Emerson Unidrive SPM User Manual

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Page 1

User Guide

Unidrive SPM

Universal Variable Speed AC Drive Modular Solutions for induction and servo motor applications

Part Number: 0471-0053-03 Issue: 3

www.controltechniques.com

Page 2

General Information

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with the motor.

The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the guide, without notice.

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

Drive software version

This product is supplied with the latest version of software. If this product is to be used in a new or existing system with other drives, there may be some differences between their software and the software in this product. These differences may cause this product to function differently. This may also apply to drives returned from a Control Techniques Service Centre.

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

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

Environmental statement

Control Techniques is committed to minimising the environmental impacts of its manufacturing operations and of its products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is certified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and other relevant information is available on request, or can be found at www.greendrives.com.

The electronic variable-speed drives manufactured by Control Techniques have the potential to save energy and (through increased machine/process efficiency) reduce raw material consumption and scrap throughout their long working lifetime. In typical applications, these positive environmental effects far outweigh the negative impacts of product manufacture and end-of-life disposal.

Nevertheless, when the products eventually reach the end of their useful life, they can very easily be dismantled into their major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, while other parts are secured with conventional screws. Virtually all parts of the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in the same way. Control Techniques' packaging strategy favours easily-recyclable materials of low environmental impact, and regular reviews identify opportunities for improvement.

When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

Page 3

How to use this guide

NOTE

1 Safety information

3 Product information

5 Mechanical installation

6 Electrical installation

7 Getting started

8 Basic parameters

9 Running the motor

10 Optimisation

11 SMARTCARD operation

13 Advanced parameters

14 Technical data

15 Diagnostics

16 UL listing information

12 Onboard PLC

4 System configuration

2 Introduction

This guide provides complete information for installing and operating a Unidrive SPMA and SPMD, with a SPMC or SPMU rectifier, 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 to 5:

Page 4

Contents

Declaration of Conformity ....................... 6

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

1.6 Motor .....................................................................7

1.7 Adjusting parameters ............................................7

2 Introduction ............................................8

2.1 Rectifier (SPMC/U) ................................................8

2.2 SPMA inverter .......................................................9

2.3 SPMD inverter .....................................................10

2.4 Input line reactor .................................................10

2.5 Output sharing choke ..........................................10

2.6 Model number .....................................................11

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

3.1 Ratings ................................................................12

3.2 Operating modes .................................................17

3.3 Compatible encoders ..........................................17

3.4 Features ..............................................................18

3.5 Nameplate description ........................................19

3.6 Options ................................................................20

3.7 Items supplied with the drive ...............................24

4 System configuration ..........................25

5 Mechanical Installation .......................33

5.1 Safety information ...............................................33

5.2 Planning the installation ......................................33

5.3 Terminal cover removal .......................................33

5.4 Solutions Module installation/removal .................37

5.5 Mounting of control master/slave pod .................38

5.6 Docking a Unidrive SPMC/U to an SPMD ...........39

5.7 Mounting methods ...............................................41

5.8 Enclosure ............................................................49

5.9 Heatsink fan operation ........................................54

5.10 Enclosing drive for high environmental

protection ............................................................56

5.11 External EMC filter ..............................................58

5.12 Line reactor mounting dimensions ......................61

5.13 Electrical terminals ..............................................62

5.14 Routine maintenance ..........................................63

6 Electrical Installation .......................... 64

6.1 Power connections ............................................. 65

6.2 AC supply requirements ..................................... 67

6.3 Output sharing choke specification .................... 69

6.4 Supplying the drive with DC / DC bus paralleling 70

6.5 Resistor sizing for Unidrive SPMU softstart ....... 70

6.6 Heatsink fan supply ............................................ 73

6.7 Control 24Vdc supply ......................................... 73

6.8 Low voltage DC power supply ............................ 73

6.9 Ratings ............................................................... 74

6.10 Output circuit and motor protection .................... 75

6.11 Braking ............................................................... 77

6.12 Ground leakage .................................................. 79

6.13 EMC (Electromagnetic compatibility) ................. 79

6.14 SPMC/U control connections ............................. 87

6.15 Low voltage DC mode enable, heatsink fan supply connections (SPMA/D) and status

input connections (SPMD) ................................. 90

6.16 Serial communications connections ................... 92

6.17 Control connections - master interface .............. 92

6.18 Encoder connections .......................................... 96

6.19 SAFE TORQUE OFF (SECURE DISABLE) ....... 99

7 Getting Started.................................. 101

7.1 Understanding the display ................................ 101

7.2 Keypad operation ............................................. 101

7.3 Menu structure ................................................. 102

7.4 Menu 0 ............................................................. 103

7.5 Advanced menus ............................................. 104

7.6 Changing the operating mode .......................... 105

7.7 Saving parameters ........................................... 105

7.8 Restoring parameter defaults ........................... 105

7.9 Parameter access level and security ............... 106

7.10 Displaying parameters with non-default values

only ................................................................... 107

7.11 Displaying destination parameters only ........... 107

7.12 Serial communications ..................................... 107

8 Basic parameters .............................. 109

8.1 Single line descriptions .................................... 109

8.2 Full descriptions ............................................... 114

9 Running the motor ............................ 124

9.1 Quick start Connections ................................... 124

9.2 Changing the operating mode .......................... 124

9.3 Changing keypad mode ................................... 124

9.4 Quick Start commissioning/start-up ................. 128

9.5 Quick start commissioning/start-up (CTSoft) ... 132

9.6 Setting up a feedback device ........................... 132

4 Unidrive SPM User Guide

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Page 5

10 Optimization ......................................136

10.1 Motor map parameters ......................................136

10.2 Maximum motor rated current ...........................146

10.3 Current limits .....................................................146

10.4 Motor thermal protection ...................................146

10.5 Switching frequency ..........................................147

10.6 High speed operation ........................................147

11 SMARTCARD operation .................... 149

11.1 Introduction .......................................................149

11.2 Transferring data ...............................................150

11.3 Data block header information ..........................152

11.4 SMARTCARD parameters ................................152

11.5 SMARTCARD trips ...........................................153

15 Diagnostics ........................................275

15.1 Trip indications ..................................................275

15.2 Alarm indications ...............................................292

15.3 Status indications ..............................................292

15.4 Displaying the trip history ..................................293

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

16 UL Listing Information ......................294

16.1 Common UL information ...................................294

16.2 Power dependant UL information .....................294

16.3 AC supply specification .....................................294

16.4 Maximum continuous output current .................294

16.5 Safety label .......................................................294

16.6 UL listed accessories ........................................294

12 Onboard PLC .....................................155

12.1 Onboard PLC and SYPTLite .............................155

12.2 Benefits .............................................................155

12.3 Limitations .........................................................155

12.4 Getting started ..................................................156

12.5 Onboard PLC parameters .................................156

12.6 Onboard PLC trips ............................................157

12.7 Onboard PLC and the SMARTCARD ...............157

13 Advanced parameters .......................158

13.1 Menu 1: Frequency / speed reference ..............166

13.2 Menu 2: Ramps .................................................170

13.3 Menu 3: Frequency slaving, speed feedback

and speed control .............................................173

13.4 Menu 4: Torque and current control ..................178

13.5 Menu 5: Motor control .......................................182

13.6 Menu 6: Sequencer and clock ..........................187

13.7 Menu 7: Analog I/O ...........................................189

13.8 Menu 8: Digital I/O ............................................192

13.9 Menu 9: Programmable logic, motorized pot,

binary sum and timers .......................................195

13.10 Menu 10: Status and trips .................................198

13.11 Menu 11: General drive set-up .........................199

13.12 Menu 12: Threshold detectors, variable

selectors and brake control function .................200

13.13 Menu 13: Position control .................................206

13.14 Menu 14: User PID controller ............................212

13.15 Menus 15, 16 and 17: Solutions Module set-up 215

13.16 Menu 18: Application menu 1 ...........................251

13.17 Menu 19: Application menu 2 ...........................251

13.18 Menu 20: Application menu 3 ...........................251

13.19 Menu 21: Second motor parameters ................252

13.20 Menu 22: Additional Menu 0 set-up ..................253

13.21 Advanced features ............................................254

List of figures .................................... 295

List of tables ..................................... 297

Index .................................................. 299

14 Technical Data ...................................263

14.1 Drive ..................................................................263

14.2 Optional external EMC filters ............................273

Unidrive SPM User Guide 5 Issue Number: 3 www.controltechniques.com

Page 6

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

Declaration of Conformity

SPMA1401 SPMA1402 SPMA1421 SPMA1422

SPMA1601 SPMA1602 SPMA1621 SPMA1622

SPMD1201 SPMD1202 SPMD1203 SPMD1204

SPMD1221 SPMD1222 SPMD1223 SPMD1224

SPMD1401 SPMD1402 SPMD1403 SPMD1404

SPMD1421 SPMD1422 SPMD1423 SPMD1424

SPMD1601 SPMD1602 SPMD1603 SPMD1604

SPMD1621 SPMD1622 SPMD1623 SPMD1624

SPMC1402 SPMC1601 SPMC2402 SPMC2601

SPMU1402 SPMU1601 SPMU2402 SPMU2601

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

EN 61800-3

EN 61000-6-2

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

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

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

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

Executive Vice President, Technology

Newtown

Date: 7th March 2007

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

6 Unidrive SPM User Guide

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Page 7

Safety

WARNING

CAUTION

NOTE

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

1 Safety Information

1.1 Warnings, Cautions and Notes

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

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

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

1.2 Electrical safety - general warning

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

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

1.3 System design and safety of

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

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

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

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

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

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

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

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

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

personnel

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

1.4 Environmental limits

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

1.5 Compliance with regulations

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

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

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

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

1.6 Motor

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

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

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

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

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

1.7 Adjusting parameters

Some parameters have a profound effect on the operation of the drive. They must not be altered without careful consideration of the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering.

Independent approval by BGIA has been given.

Unidrive SPM User Guide 7 Issue Number: 3 www.controltechniques.com

Page 8

Safety

CAUTION

+DC

-DC

L3A

+DC (A)

-DC (A)

L2A

L1A

L3B

+DC (B)

-DC(B)

L2B

L1B

+DC

-DC

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

2 Introduction

The Unidrive Solutions Platform Modular drive offers the possibility of implementing many custom power systems with a wide range of power modules. The power range is 45kW to 1.9MW and the modular design of input and output stages enables a wide range of very compact and efficient systems to be realized. These include:

• Parallel output stages for higher power motors: Up to a maximum of 10 SPMA/D modules (1 master module with up to 9 slave modules, OR 1 remote mounted control master pod controlling up to 10 slaves. This allows the user to place all circuitry in one low voltage cabinet)

• Common DC bus multi-drive systems for: Connection to larger existing power supplies Energy sharing between motoring and regenerating drives

• Active front end drive systems for: Minimising supply current harmonics Four quadrant motor control

• Multiple controlled rectifier bridges (SPMC) for: Minimising supply current harmonics by drawing 6, 12 or 18 pulse supply load currents

• Uncontrolled rectifier bridges (SPMU) for use in applications with

poor quality power supplies, very long motor cables and where DC bus pre-charge is done by other means

2.1 Rectifier (SPMC/U)

There are two distinct types of rectifier available

SPMC: Controlled SCR/thyristor rectifier SPMU: Uncontrolled diode rectifier

Different current and voltage ratings are available for both types.

2.1.1 Half controlled SCR/thyristor rectifier (SPMC)

The half controlled SCR/thyristor bridge is used as a front end to the SPMD inverter module or as a stand alone rectifier for several smaller drives. Control wiring is linked to the inverter for trip monitoring. Softstart is built in.

SPMC14X2 and 16X1

Figure 2-1 Single half controlled SCR/thyristor

SPMC2X0X

Figure 2-2 Dual half controlled SCR/thyristor

A separate input line reactor (INLXXX) of at least the value shown in Table 6-2 and Table 6-3 on page 68 must be used with the rectifiers. Failure to provide sufficient reactance could damage or reduce the service life of the rectifier or inverter.

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

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

An external 24V, 3A power supply is required in addition to the AC supply to allow the rectifier to operate. See section 6.14.3 Unidrive

SPMC/U control connections on page 89 and section 14.1.4 Unidrive SPM 24V power supply on page 267. Control wiring is required between

the rectifier and motoring drive(s) so that if the rectifier indicates a fault the motoring drive(s) will be disabled.

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

Control connections to the Unidrive SPMC/U should be made with

0.5mm

cable.

The status relay contacts are rated for switching non-inductive loads at 250Vac 6A non-inductive, up to 4Adc if the voltage is limited to 40V or up to 400mA dc if the voltage is limited to 250Vdc. Protection from overcurrent must be provided.

2.1.2 Diode rectifier (SPMU)

The uncontrolled diode rectifier is supplied as an alternative to the half controlled SCR/thyristor rectifier. Control wiring is limited to a thermal trip. Soft-start is achieved by the use of an external contactor and resistor.

SPMU14X2 and 16X1

Figure 2-3 Single diode rectifier

8 Unidrive SPM User Guide

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Page 9

Safety

L1A

L2A

L3A

+DC (A)

-DC (A)

L1B

L2B

L3B

+DC (B)

-DC (B)

NOTE

+DC

-DC

Optional

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

SPMU24X2 and SPMU26X1

Figure 2-4 Dual diode rectifier

To gain access to the second power stage terminals, the housing covers must be removed. See Figure 5-3 on page 35.

Tec h ni c al

Data

Diagnostics

UL Listing

Information

2.2 SPMA inverter

The SPMA is a complete drive with internal rectifier and AC input line chokes (AC in to AC out). It can provide a maximum continuous output current of 236A (400V drive). DC connections are available for use in regen and bus-parallel applications. The SPMA is available with or without a braking IGBT fitted.

Figure 2-5 SPMA inverter schematic

Unidrive SPM User Guide 9 Issue Number: 3 www.controltechniques.com

Page 10

Safety

UVW

+DC

-DC

+DC

Optional

L1A

L2A

L3A

L1A

L2A

L3A

L1B

L2B

L3B

Supply

Drive 1

Drive 2

NOTE

UVW

U1 U2

V1 V2

W1 W2

Drive 1

Drive 2

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

2.3 SPMD inverter

The SPMD is an inverter stage only (DC in to AC out). If a rectifier is required, then an SPMC or SPMU and AC input line reactor must also be installed. It can provide a maximum continuous output current of 350A (400V drive). DC connections can be used for regen and bus-parallel applications. The SPMD is available with or without a braking IGBT fitted.

Figure 2-6 SPMA inverter schematic

2.4 Input line reactor

The INL line reactor must be used in conjunction with the Unidrive SPMC/U rectifiers. See section 6.2.2 Input line reactor specifications on page 67 for further information.

Figure 2-7 Single input line reactor (INLX0X)/force cooled (INLX0XW)

Figure 2-8 Dual input line reactor (INLX1X)

2.5 Output sharing choke

The OTL output sharing choke must be used on the output of Unidrive SPMA/D when more than one module is paralleled together.

Figure 2-9 Single output sharing choke (OTLX0X)

Figure 2-10 Dual output sharing choke (OTLX1X)

This is not an interbridge reactor.

For a physical representation of the input line reactors and output sharing chokes, see Figure 3-4 on page 21.

10 Unidrive SPM User Guide

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Page 11

Safety

Unidrive SPM product line

SPMC:

Number of rectifier stages

Voltage rating

Current rating step

SPMU:

Uncontrolled rectifier

SPMC 1 402

Controlled rectifier

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

Unidrive SPM product line

SPMA:

SPM frame size

Voltage rating

Configuration

Current rating step

SPMD:

Power module power stages for custom drive systems DC input

SPMA

1 4 0 1

Power module power stages for custom drive systems AC input

1: Size 1

2: 200V to 240V (SPMD only) 4: 380V to 480V 6: 500V to 690V

Indicates if an internal brake transistor is fitted:

0: Brake fitted 2: Brake not fitted

NOTE

INL:

Current rating step

OTL:

Output sharing choke

INL

401

Input line reactor

0: Single 1: Dual

Voltage rating

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

Single input line reactor type:

Blank:W:Standard copper foil wound

Wirewound

NOTE

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

parameters

2.6 Model number

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

Figure 2-11 Rectifier (SPMC and SPMU)

Figure 2-12 Drives (SPMA and SPMD)

Basic

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Tec h ni c al

Data

Figure 2-13 Input line reactor / output sharing choke

The wirewound type of input line reactor is the minimum material version. Minimum airflow and maximum ambient temperature must be maintained. Refer to Table 14-24 on page 270.

Diagnostics

UL Listing

Information

200V to 240V SPMD modules can only be supplied by an SPMU or separate soft start circuit.

Unidrive SPM User Guide 11 Issue Number: 3 www.controltechniques.com

Page 12

Safety

Available output

current

Overload limit -

Heavy Duty

Maximum continuous current (above 50% base speed) -

Normal Duty

Maximum continuous current -

Heavy Duty

Motor rated current set in the drive

Heavy Duty

- with high

overload capability

Normal Duty

Overload limit -

Normal Duty

NOTE

Motor total

current (Pr 4.01)

as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible continuous current

100%

I t protection operates in this region

70%

50%15%

Pr = 0 Pr = 1

4.25

Motor total

current (Pr 4.01)

as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible

continuous current

100%

I t protection operates in this region

70%

50%

Pr = 0

Pr = 1

4.25

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

Basic

parameters

3 Product Information

3.1 Ratings

The Unidrive SPM 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.

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Te ch n ic a l

Data

Diagnostics

UL Listing

Information

Normal Duty Heavy Duty (default)

For applications which use self ventilated (TENV/TEFC) induction motors and require a low overload capability (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 operates at a level which is speed dependent. This is illustrated in the graph below.

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

Operation of motor I2t protection (It.AC trip)

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

• Self ventilated (TENV/TEFC) induction motors

t software

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

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

Motor I2t protection defaults to be compatible with:

• Forced ventilation induction motors

• Permanent magnet servo motors

12 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Page 13

Safety

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System

configuration

Mechanical Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

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Optimization

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Onboard

PLC

Advanced

parameters

Technical

Data

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UL Listing

Information

The continuous current ratings given are for maximum 40°C (104°F), 1000m altitude and 3.0 kHz switching. Derating is required for higher switching frequencies, ambient temperature >40°C (104°F), high altitude and parallel applications. For further information, refer to section 14.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 263.

Table 3-1 SPMA 400V drive ratings (380V to 480V ±10%)

Normal Duty Heavy Duty

Model

Maximum

continuous

output

current

Peak

current

Nominal

motor power

at 400V

Nominal

motor power

at 460V

Maximum

continuous

output

current

Open

loop peak

current

Closed

loop peak

current

Nominal

motor power

at 400V

AAkW hp A AA kW hp A

SPMA14X1 205 225 110 150 180 232 270 90 150

SPMA14X2 236 259 132 200 210 271 315 110 150

Nominal

motor power

at 460V

External 24V

current

consumption

3.3

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

Normal Duty Heavy Duty

Required

output

sharing

choke

Paralleled SPMA modules

2 x SPMA14X1

2 x SPMA14X2 448 493 250 400 399 513 598 225 350 1 x OTL412

3 x SPMA14X1 584 642 315 500 513 659 769 280 450 3 x OTL401

3 x SPMA14X2 672 739 355 550 598 769 897 315 500 3 x OTL402

4 x SPMA14X1 779 859 400 650 684 878 1025 355 600 4 x OTL401

4 x SPMA14X2 896 986 500 750 798 1026 1197 400 700 4 x OTL402

5 x SPMA14X1 973 1071 550 850 855 1098 1281 450 750 5 x OTL401

5 x SPMA14X2 1121 1233 600 950 997 1282 1496 550 850 5 x OTL402

6 x SPMA14X1 1168 1285 650 1000 1026 1318 1538 550 900 6 x OTL401

6 x SPMA14X2 1345 1479 750 1150 1197 1539 1795 650 1050 6 x OTL402

Maximum

continuous

output

current

Peak

current

Nominal

motor

power at

400V

Nominal

motor

power at 460V

Maximum

continuous

output

current

Open

loop peak

current

Closed

loop peak

current

Nominal

motor

power

at 400V

Nominal

motor

power at 460V

AAkW hp A AAkW hp

389 428 225 300 342 439 512 185 300 1 x OTL411

When connecting drives in parallel they must be derated. Table 3-2, Table 3-4, Table 3-6, Table 3-8 and Table 3-10 have already the required de-rating.

Table 3-3 SPMA 690V drive ratings (500V to 690V ±10%)

Model

SPMA16X1

SPMA16X2

Normal Duty Heavy Duty

Maximum

continuous

output

current

Peak

current

Nominal

motor

power

at 690V

Nominal

motor power

at 575V

Maximum

continuous

output

current

Open

loop

peak

current

Closed

loop

peak

current

Nominal

motor power

at 690V

Nominal

motor power

at 575V

AAkW hp A AA kW hp A

125 137 110 125 100 128 149 90 100

144 158 132 150 125 160 187 110 125

External 24V

current

consumption

3.3

Unidrive SPM User Guide 13 Issue Number: 3 www.controltechniques.com

Page 14

Safety

NOTE

CAUTION

NOTE

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Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

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parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Te ch n ic a l

Data

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Information

Table 3-4 Paralleled SPMA 690V motor drive ratings (500V to 690V ±10%)

Normal Duty Heavy Duty

Paralleled SPMA modules

2 x SPMA16X1 237 261 250 250 190 244 284 200 200 1 x OTL611

2 x SPMA16X2 273 300 280 300 237 305 356 250 250 1 x OTL612

3 x SPMA16X1 356 391 355 400 285 366 427 300 300 3 x OTL601

3 x SPMA16X2 410 451 450 450 356 457 534 355 400 3 x OTL602

4 x SPMA16X1 475 522 500 500 380 488 569 400 400 4 x OTL601

4 x SPMA16X2 547 601 560 600 475 610 712 500 500 4 x OTL602

5 x SPMA16X1 593 653 610 600 475 610 712 500 500 5 x OTL601

5 x SPMA16X2 684 752 710 700 593 763 890 610 600 5 x OTL602

6 x SPMA16X1 712 783 710 800 570 732 854 610 600 6 x OTL601

6 x SPMA16X2 820 902 875 900 712 915 1068 710 800 6 x OTL602

Maximum

continuous

output

current

AAkWhp AAAkWhp

Peak

current

Nominal

motor power

at 690V

Nominal

motor power

at 575V

Maximum

continuous

output

current

Open

loop

peak

current

Closed

loop peak

current

Nominal

motor

power

at 690V

Nominal

motor power

at 575V

Required

output sharing

choke

The Unidrive SPMD can be connected to its rectifier module in two ways, directly above the inverter (docked) or independently mounted in different vertical planes (undocked). Changes in the flow of air mean that the ratings are different for the two mounting methods for SPMD12x4. For details on docking, refer to section 5.6 Docking a Unidrive SPMC/U to an SPMD on page 39.

Table 3-5 SPMD 200V drive ratings (200V to 240V ±10%) based on AC supply voltage

Normal Duty Heavy Duty

Maximum

Model

SPMD12X1* 192 211 55 75 156 201 234 45 60

SPMD12X2* 248 272 75 100 192 247 288 55 75

SPMD12X3* 312 343 90 125 250 322 375 75 100

SPMD12X4** 335 365 90 125 290 374 435 90 125

SPMD12X4*** 350 385 110 150 290 374 435 90 125

continuous

output

current

AAkWhpA AAkWhp

Peak

Nominal

motor

power at

230V

Nominal

motor

power at

230V

Maximum

continuous

output

current

Open

loop

peak

current

Closed

loop peak

current

Nominal

motor power

at 230V

Nominal

motor

power at

230V

Required

rectifier

1 x

SPMU1402

Required input line

reactor

INL401

INL402

1 x

External 24V

current

consumption

3.3

*SPMD12X1 to 12X3 ratings apply with the rectifier docked and undocked. **SPMD12X4 rating with the rectifier docked. The overload rating for the SPMD12X4 is only available if the ambient temperature is 35°C or lower. ***SPMD12X4 rating with the rectifier undocked. The maximum continuous output current and overload rating for the SPMD12X4 is only available if the ambient temperature is 35°C or lower.

When using an SPMU a separate soft start circuit must be provided for the DC bus. Refer to Figure 4-6 on page 30 and section 6.5 Resistor sizing for Unidrive SPMU softstart on page 70.

Table 3-6 Paralleled SPMD 200V motor drive ratings (200V to 240V ±10%) based on AC supply voltage

Normal Duty Heavy Duty

Paralleled SPMD modules

2 x SPMD12X1

2 x SPMD12X2

2 x SPMD12X3

2 x SPMD12X4

Maximum

continuous

output

current

AAkWhp AAAkWhp

364 401 110 150 296 381 444 90 125

471 518 132 200 364 468 546 110 150 1 x INL411

592 652 160 250 475 610 712 150 200

636 700 200 250 551 708 826 160 200

Peak

Nominal

motor

power at

230V

Nominal

motor

power at

230V

Maximum

continuous

output

current

Open

loop peak

current

Closed

loop peak

current

Nominal

motor power

at 230V

Nominal

motor

power at

230V

Required

rectifier

1 x

SPMU2402

Required

reactor

1 x INL411

INL412

The Unidrive SPMD can be connected to its rectifier module in two ways, directly above the inverter (docked) or independently mounted in different vertical planes (undocked). Changes in the flow of air mean that the ratings are different for the two mounting methods for SPMD14x4. For details on docking, refer to section 5.6 Docking a Unidrive SPMC/U to an SPMD on page 39.

14 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

line

1 x

Required

output

sharing

choke

1 x

OTL411

1 x

OTL412

1 x

OTL413

1 x

OTL414

Page 15

Safety

NOTE

Information

Introduction

Product

Information

System

configuration

Mechanical Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

Table 3-7 SPMD 400V motor drive ratings (380V to 480V ±10%) based on AC supply voltage

Normal Duty Heavy Duty

Maximum

Model

SPMD14X1* 205 225 110 150 180 232 270 90 150

SPMD14X2* 246 270 132 200 210 271 315 110 150

SPMD14X3* 290 319 160 250 246 310 359 132 200

SPMD14X4***

continuous

output current

AAkWhp AAAkWhp

350 385 200 300 290 374 435 160 250

Peak

current

Nominal

motor

power at

400V

Nominal

motor

power at

460V

Maximum

continuous

output

current

Open

loop peak

current

Closed

loop peak

current

Nominal

motor power

at 400V

Nominal

motor

power at

460V

Required

rectifier

1 x

SPMC1402

Required input line

reactor

1 x INL401 3.3

1 x INL402 4.5SPMD14X4** 335 365 185 300 290 374 435 160 250

External 24V

current

consumption

*SPMD14X1 to 14X3 ratings apply with the rectifier docked and undocked. **SPMD14X4 rating with the rectifier docked. The overload rating for the SPMD14X4 is only available if the ambient temperature is 35°C or lower.

***SPMD14X4 rating with the rectifier undocked. The maximum continuous output current and overload rating for the SPMD14X4 is only available if the ambient temperature is 35°C or lower.

Table 3-8 Paralleled SPMD 400V motor drive ratings (380V to 480V ±10%) based on AC supply voltage

Normal Duty Heavy Duty

Paralleled SPMD modules

2 x SPMD14X1 389 428 225 300 342 439 512 185 300 2 x SPMD14X2 467 514 280 400 399 513 598 225 300 1 x OTL412 2 x SPMD14X3 551 606 315 450 467 586 683 280 400 2 x SPMD14X4 636 700 355 500 551 708 826 315 450 1 x OTL414

3 x SPMD14X2 701 771 400 600 598 769 897 315 500

4 x SPMD14X1 779 856 450 650 684 878 1025 355 600 2 x SPMC2402 2 x INL411 4 x OTL401

3 x SPMD14X3 826 909 450 700 701 879 1025 400 650

4 x SPMD14X2 934 1028 500 800 798 1026 1197 450 700 2 x SPMC2402 2 x INL411 4 x OTL402

3 x SPMD14X4 954 1050 560 800 826 1062 1239 450 750

4 x SPMD14X3 1102 1212 630 900 934 1172 1367 550 800 4 x SPMD14X4 1272 1400 710 1000 1102 1416 1652 630 900 2 x INL412 4 x OTL404

Maximum

continuous

output

current

400V

Nominal

motor

power at

460V

Maximum

continuous

output

current

AAkWhp A AAkWhp

Peak

Nominal

motor

power at

Open

loop peak

current

loop peak

current

at 400V

Nominal

Closed

motor

power

Nominal

motor

power at

460V

Required

rectifier

1 x SPMC2402

1 x SPMC2402 +

1 x SPMC1402

1 x SPMC2402 +

1 x SPMC1402

1 x SPMC1402 +

1 x SPMC2402

2 x SPMC2402

Required input line

reactor

1 x INL411

1 x INL412

1 x INL411 +

1 x INL401

1 x INL412 +

1 x INL402

1 x INL412 +

1 x INL402 2 x INL412 4 x OTL403

Required

output

sharing

choke

1 x OTL411

1 x OTL413

3 x OTL402

3 x OTL403

3 x OTL404

When connecting drives in parallel they must be derated. Table 3-2, Table 3-4, Table 3-6, Table 3-8 and Table 3-10 have already the required de-rating.

Table 3-9 SPMD 690V motor drive ratings (500V to 690V ±10%)

Normal Duty Heavy Duty

Maximum

Model

SPMD16X1 125 137 110 125 100 129 150 90 100

SPMD16X2 144 158 132 150 125 161 188 110 125

SPMD16X3 168 184 160 150 144 185 216 132 150

SPMD16X4 192 211 160 200 168 216 252 150 150

continuous

output

current

AAkW

Peak

current

Nominal

motor power

at 690V

Nominal

motor power

at 575V

Maximum

continuous

output

current

AAAkW

Open

loop

peak

current

Closed

loop

peak

current

Nominal

motor

power

at 690V

Nominal

motor power

at 575V

Required

rectifier

Required input line

reactor

hp A

1 x INL601 3.3

1 x

SPMC/U1601

1 x INL602 4.5

External 24V

current

consumption

Unidrive SPM User Guide 15 Issue Number: 3 www.controltechniques.com

Page 16

Safety

NOTE

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Table 3-10 Paralleled SPMD 690V motor drive ratings (500V to 690V ±10%) based on AC supply voltage

Normal Duty Heavy Duty

Paralleled SPMD modules

2 x SPMD16X1 237 261 250 250 190 244 284 200 200

2 x SPMD16X2 273 300 280 300 237 305 356 250 250 1 x OTL612 2 x SPMD16X3 319 351 315 350 273 351 410 250 300 2 x SPMD16X4 364 401 315 350 319 410 478 280 350 2 x SPMC1601 1 x OTL614

3 x SPMD16X2 410 451 450 450 356 457 534 355 400

3 x SPMD16X3 478 526 500 500 410 527 615 450 450

3 x SPMD16X4 547 601 545 600 478 615 718 450 500 3 x SPMC1601 3 x OTL604

4 x SPMD16X3 638 702 630 700 547 703 820 545 600 2 x SPMC2601

4 x SPMD16X4 729 802 710 800 638 820 957 630 700 4 x SPMC1601 4 x OTL604

Maximum

continuous

output

current

A AkW hp A AAkWhp

Peak

current

Nominal

motor

power at

690V

Nominal

motor

power at

575V

Maximum

continuous

output

current

Open

loop

peak

current

Closed

loop peak

current

Nominal

motor power

at 690V

Nominal

motor

power at

575V

When connecting drives in parallel they must be derated. Table 3-2, Table 3-4, Table 3-6, Table 3-8 and Table 3-10 have already the required de-rating.

Table 3-11 Unidrive SPMC/U 400V ratings

External 24V

current

consumption

Model

Maximum

AC input current

AAA

Maximum DC

output current

Advanced

parameters

1 x SPMC2601

1 x SPMC1601

Required

rectifier

Te ch n ic a l

Diagnostics

Data

Required input line

reactor

1 x INL611

1 x INL612

1 x INL611 +

1 x INL601

1 x INL612 +

1 x INL602

2 x INL612

UL Listing

Information

Required

output

sharing

choke

1 x OTL611

1 x OTL613

3 x OTL602

3 x OTL603

4 x OTL603

SPMC/U1402

SPMC/U2402

344 379

3.0

2 x 312 2 x 345

Table 3-12 Unidrive SPMC/U 690V ratings

External 24V

current

consumption

3.0

Model

SPMC/U1601 195

SPMC/U2601 2 x 173

Maximum AC input

current

AAA

Maximum DC

output current

209

2 x 185

3.1.1 Typical short term overload limits

The maximum percentage overload limit changes depending on the selected motor. Variations in motor rated current, motor power factor and motor leakage inductance all result in changes in the maximum possible overload. The exact value for a specific motor can be calculated using the equations detailed in Menu 4 in the Unidrive SP Advanced User Guide. Typical values are shown in the tables below for closed loop vector (VT) and open loop (OL) modes.

Table 3-13 Typical overload limits for all Unidrive SPM modules

Operating mode

Normal Duty overload with motor rated current = drive rated current 110% for 165s 110% for 9s 110% for 165s 110% for 9s Heavy Duty overload with motor rated current = drive rated current 150% for 60s 150% for 8s 129% for 97s 129% for 15s

Closed loop/RFC/

Servo/Regen from cold

Closed loop/RFC/Servo/

Regen from 100%

Open loop from cold Open loop from 100%

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

16 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Page 17

Safety

Information

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configuration

Mechanical Installation

Electrical

Installation

Getting Star ted

Basic

parameters

3.2 Operating modes

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

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

2. RFC mode

3. Closed loop vector

4. Servo

5. Regen

3.2.1 Open loop mode

For use with induction motors. 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 1Hz for a 50Hz motor. For further details refer to section 10.1.1 Open loop motor control on

page 136.

Fixed V/F mode

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

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

Quadratic V/F mode

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

3.2.2 RFC mode

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

For further details refer to section 10.1.2 RFC mode on page 138.

3.2.3 Closed loop vector mode

For use with induction motors with a feedback device installed. The drive directly controls the speed of the motor using the feedback

device to ensure the rotor speed is exactly as demanded. Motor flux is accurately controlled at all times to provide full torque all the way down to zero speed.

For further details refer to section 10.1.3 Closed loop vector motor control on page 141.

Running

the motor

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parameters

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Data

Diagnostics

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For further details refer to section 10.1.4 Servo motor control on page 144.

3.2.5 Regen

For use as a regenerative front end for four quadrant operation. Regen operation allows bi-directional power flow to and from the AC

supply. This provides far greater efficiency levels in applications which would otherwise dissipate large amounts of energy in the form of heat in a braking resistor.

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

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

3.3 Compatible encoders

Table 3-14 Encoders compatible with Unidrive SPM

Encoder type Pr 3.38 setting

Quadrature incremental encoders with or without marker pulse

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

Forward / reverse incremental encoders with or without marker pulse

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

Frequency and direction incremental encoders with or without marker pulse

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

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

for absolute position Stegmann sincos encoders with Hiperface comms

for absolute position Sincos encoders with SSI comms for absolute

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

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

Ab (0)

Ab.SErvo (3)

Fr (2)

Fr.SErvo (5)

Fd (1)

Fd.SErvo (4)

SC.EndAt (9)

SC.HiPEr (7)

SC.SSI (11)

3.2.4 Servo

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

The drive directly controls the speed of the motor using the feedback device to ensure the rotor speed is exactly as demanded. Flux control is not required because the motor is self excited by the permanent magnets which form part of the rotor.

Absolute position information is required from the feedback device to ensure the output voltage is accurately matched to the back EMF of the motor. Full torque is available all the way down to zero speed.

Unidrive SPM User Guide 17 Issue Number: 3 www.controltechniques.com

Page 18

Safety

Solutions Module slot 2

SMARTCARD slot

Keypad connection

Serial port connector

Encoder connection

Control terminals

Solutions Module slot 1

Solutions Module slot 3

Rating label

Status LED

Approvals label B

Relay terminals

supply

Internal

EMC filter

supply

Motor

connections

Low voltage DC mode enable / heatsink fan supply connections

Brake

resistor

Control master pod Control slave pod

SPMA

Motor

connections

Low voltage DC mode

enable / heatsink fan

supply connections /

rectifier status inputs

Brake

resistor

SPMD

supply

Internal

EMC filter

supply

SPMC/U

Output connections

to slave

Input from Master /

Output to slave

Internal

EMC filter

supply

Internal

EMC filter

supply

output

Status

LEDs

Approvals

label A

Approvals label A

Rating

label

Status LED

Cover Base

Control

terminals

NOTE

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

3.4 Features

Figure 3-1 Features of the Unidrive SPM Modules

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Te ch n ic a l

Data

Diagnostics

UL Listing

Information

24V supply is required for fans on all modules.

18 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Page 19

Safety

Rating label

(SPMA / SPMD - Master and Slave)

S.No:

3000005001

Serial number

Please read manual before connecting.

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

Ser No:

3000005001

Serial number

Approvals label B

(SPMA / SPMD - Master only)

Model

Heavy Duty / Normal Duty power rating

Customer and date code

Approvals

Please read manual before connecting.

SPMA1601 90 / 110kW

STDN39

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

Ser No: 3000005001

Made In U.K

Serial number

SP 100 TH

Approvals label A

(SPMA / SPMD - Master and Slave)

I/P 500-690V 50-60Hz 3ph 128.0A O/P 0-690V

100 / 125A

Input voltage

Output voltage

Input

frequency

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

Heavy Duty /

Normal Duty

rating output current

Rectifier rating label

(SPMC / SPMU only)

Status1 Status0

I/P 380-480V 50-60Hz 3ph 204A O/P 513-648V 219A

SPMC1401

Ser No:

3000005001

STDN39

Customer and

date code

Serial number

Approvals

Model

Input voltage, frequency, no. of phases and current

Output voltage and current

Status

LEDs

CE approval Europe

C Tick approval Australia

UL / cUL approval

USA &

Canada

Key to approvals

Information

Introduction

Product

Information

System

configuration

Mechanical Installation

Electrical

Installation

Getting Star ted

Basic

parameters

Running

the motor

3.5 Nameplate description

See Figure 3-1 Features of the Unidrive SPM Modules for location of rating labels.

Figure 3-2 Typical drive rating labels

Optimization

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Unidrive SPM User Guide 19 Issue Number: 3 www.controltechniques.com

Page 20

Safety

WARNING

CT Comms cable

Feedback Automation Fieldbus

Keypad

SMARTCARD*

Paralleling cable**

Master interface

Slave interface

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

3.6 Options

Power down the drive before installing / removing the Solutions Module.

Figure 3-3 Control options available with Unidrive SPM

Getting Star ted

Basic

parameters

Running

the motor

Optimization

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operation

Onboard

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parameters

Te ch n ic a l

Data

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Information

* A SMARTCARD is provided as standard. Only one SMARTCARD can be installed at any one time. For further information, refer to Chapter 11 SMARTCARD operation on page 149.

** Paralleling cable is only supplied with a control slave pod.

20 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Page 21

Safety

Single input line reactor

(INLX0X) for use with

Unidrive SPMC/U

Single input line reactor (INL40XW) for use with

Unidrive SPMC/U

EMC filter

SPMC/U to SPMD

docking kit 3470-0012

Dual output sharing choke

(OTLX1X) for parallel

module drives

Dual input line reactor (INLX1X) for use with

Unidrive SPMC/U

Single output sharing choke

(OTLX0X) for parallel

module drives

Lifting

bracket

6541-0073

Finger-guard grommets

Single entry

kit of 4

9500-0074

Double entry kit of 4 9500-0075

CAUTION

Inputs Outputs

• Incremental encoders • Quadrature

• SinCos encoders • Frequency and direction

• SSI encoders • SSI simulated outputs

• EnDat encoders

Information

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System

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Electrical

Installation

Figure 3-4 Power options available for Unidrive SPM

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

Table 3-15 Solutions Module identification

Type Solutions Module Color Name Further Details

Feedback

A separate input line reactor of at least the value shown in Table 6-2 and Table 6-3 on page 68 must be used with the rectifiers. Failure to provide sufficient reactance could damage or reduce the service life of the rectifier or inverter.

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

Light Green

SM-Universal Encoder Plus

Light Blue SM-Resolver

Brown SM-Encoder Plus

SM-Encoder Output Plus

15-way D-type converter

Dark Brown

N/A

Single ended

N/A

encoder interface (15V)

Universal Feedback interface

Feedback interface for the following devices:

Resolver interface

Feedback interface for resolvers. Simulated quadrature encoder outputs

Incremental encoder interface

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

Incremental encoder interface

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

Drive encoder input converter

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

Single ended encoder interface

Provides an interface for 15V single ended ABZ or UVW encoder signals, such as those from hall effect sensors

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Safety

• Digital inputs x 3

• Analog output (voltage) x 1

• Digital I/O x 3 • Relay x 2

• Analog inputs (voltage) x 2

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Table 3-15 Solutions Module identification

Type Solutions Module Color Name Further Details

Additional I/O interface

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

Yellow SM-I/O Plus

existing I/O in the drive:

Additional I/O interface

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

Yellow SM-I/O 32

existing I/O in the drive:

• High speed digital I/O x 32

• +24V output

Additional I/O

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

Additional I/O with real time clock

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

Automation

(I/O

Expansion)

Dark Yellow SM-I/O Lite

Dark Red SM-I/O Timer

for scheduling drive running

Isolated I/O to NAMUR NE37 specifications

For chemical industry applications

Turquoise SM-I/O PELV

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

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Data

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Information

Automation

(Applications)

Olive SM-I/O 120V

Cobalt Blue

SM-I/O 24V Protected

Dark Green SM-Applications

White SM-Applications Lite

Dark Blue SM-EZMotion

Moss Green

SM-Applications Plus

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

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

Additional I/O with overvoltage protection up to 48V

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

Applications Processor (with CTNet)

processor for running pre-defined and /or customer created

application software with CTNet support

Applications Processor

processor for running pre-defined and /or customer created

application software

Motion Controller

/2 axis motion controller with processor for running customer

created application specific software.

Applications Processor (with CTNet)

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

22 Unidrive SPM User Guide

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Information

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Electrical

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Table 3-15 Solutions Module identification

Type Solutions Module Color Name Further Details

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

Fieldbus

Purple SM-PROFIBUS-DP

Medium Grey SM-DeviceNet

Dark Grey SM-INTERBUS

Pink SM-CAN

Light Grey SM-CANopen

Red SM-SERCOS

Beige SM-Ethernet

Profibus option

PROFIBUS DP adapter for communications with the drive

DeviceNet option

Devicenet adapter for communications with the drive

Interbus option

Interbus adapter for communications with the drive

CAN option

CAN adapter for communications with the drive

CANopen option

CANopen adapter for communications with the drive

SERCOS option

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

Ethernet option

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

Pale Green SM-LON

Brown Red SM-EtherCAT

LonWorks option

LonWorks adapter for communications with the drive

EtherCAT option

EtherCAT adapter for communication with the drive

SLM interface

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

SLM Orange SM-SLM

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

• Encoder only mode

• Host mode

Table 3-16 Keypad identification

Type Keypad Name Further Details

SM-Keypad

LED keypad option

Keypad with a LED display

Keypad

SM-Keypad Plus

LCD keypad option

Keypad with an alpha-numeric LCD display with Help function

Table 3-17 Other options

Type Option Name Further Details

Power supply

24V power supply 24V, 10A power supply (Part No: 8510-0000)

Unidrive SPM User Guide 23 Issue Number: 3 www.controltechniques.com

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Safety

CAUTION

Risk of Electric Shock

Power down unit 10minutes

before removing cover

M8x20

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Te ch n ic a l

3.7 Items supplied with the drive

The drive is supplied with a copy of the Unidrive SPM User Guide, a SMARTCARD (control master pod only), the safety booklet, the certificate of quality, an accessory kit box including the items shown in Table 3-18, and two CD ROMs. The Unidrive SPM CD ROM contains information specific to this product, and the standard Unidrive SP CD ROM contains general documentation and software tools.

Table 3-18 Accessories supplied with Unidrive SPM

Description SPMA SPMD SPMC/U

UL warning label

Nylon washers

Sealing clips

Through panel mounting gasket

Mounting bracket

Fan / control connector(s)

Data

Diagnostics

UL Listing

Information

Paralleling cable

Mounting screws

Control connectors

Relay connector

Grounding bracket

Top surface mounting brackets

Surface mounting brackets

Grounding busbar

Slave only

Master only

EMC output bracket

24 Unidrive SPM User Guide

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Page 25

UVW

Fuses*

24Vdc***

Fuses**

Safety

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

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Onboard

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Advanced

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Te ch n ic a l

Data

Diagnostics

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Information

4 System configuration

This chapter demonstrates various Unidrive SPM system configurations. A suitable external 24Vdc power supply is available from the supplier of the drive. See section 14.1.4 Unidrive SPM 24V power supply on page 267 for further details.

Figure 4-1 Layout for a Unidrive SPMA module operating on a 3-phase AC supply

*Refer to Table 6-15 on page 74 for technical data and part numbers. **Fuses are needed only if the power supply has a current rating of more than 10A. ***Refer to section 14.1.3 Supply requirements on page 267 for supply requirements.

Unidrive SPM User Guide 25 Issue Number: 3 www.controltechniques.com

Page 26

Safety

Fuses* Fuses*

OTLXXX

sharing

chokes

UVW UVW

24Vdc***

Paralleling

cable

OTLXXX sharing chokes

Fuses**

Master Slave

Information

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Electrical

Installation

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Running

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Figure 4-2 Layout for two or more Unidrive SPMA modules operating on a 3-phase AC supply

SMARTCARD

operation

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Advanced

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Technical

Data

Diagnostics

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Information

Refer to the external 24V power supply current consumption column in the ratings tables in section 3.1 Ratings on page 12.

26 Unidrive SPM User Guide

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Fuses*

UVW

+DC -DC

INLXXX

Line reactor***

Rectifier to

inverter

control wiring

Fuses**

SPMC

24Vdc****

SPMD

24Vdc****

Safety

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Installation

Electrical

Installation

Getting Star ted

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Running

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Optimization

Figure 4-3 Layout for an Unidrive SPMD module operating on a 3-phase supply

SMARTCARD

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Onboard

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Advanced

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Te ch n ic a l

Data

Diagnostics

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Information

*Refer to Table 6-16, Table 6-17 on page 74 and Table 6-18 on page 75 for technical data and part numbers. **Fuses are needed only if the power supply has a current rating of more than 10A. ***Refer to Table 6-2, Table 6-3, Table 6-4 and Table 6-5 on page 68 for technical data and part numbers.

****Refer to section 14.1.3 Supply requirements on page 267 for supply requirements.

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Safety

Fuses*

INLXXX Line reactor***

+DC

-DC

Rectifier to

inverter

control wiring

Fuses**

24V SPMD enable

24Vdc****

Fuses**

OPEN

CLOSED

OPEN

CLOSED

Under Voltage

Drive Healthy

Under

voltage

active

10.16

Switching sequence for K1 and K2

24Vdc****

*Refer to Table 6-16, Table 6-17 on page 74 and Table 6-18 on page 75 for technical data and part numbers. **Fuses are needed only if the power supply has a current rating of more than 10A.

***Refer to Table 6-2, Table 6-3, Table 6-4 and Table 6-5 on page 68 for technical data and part numbers. ****Refer to section

14.1.3 Supply requirements on page 267 for supply requirements.

For softstart circuit component sizing, refer to section 6.5 Resistor

sizing for Unidrive SPMU softstart on page 70.

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Advanced

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Data

Figure 4-4 Layout for an Unidrive SPMD module operating on a 3 phase supply with SPMU (uncontrolled) rectifier and softstart circuit

Diagnostics

UL Listing

Information

28 Unidrive SPM User Guide

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Master

Fuses* Fuses*

INLXXX Line reactor**

OTLXXX

Sharing

chokes

OTLXXX

Sharing

chokes

UVW UVW

+DC -DC +DC -DC

Rectifier control connections

Fuses***

SPMC

24Vdc****

SPMD

24Vdc****

Slave

Master/ slave

interface

lead

Rectifier to inverter control wiring

*Refer to Table 6-16, Table 6-17 on page 74 and Table 6-18 on page 75 for technical data and part numbers.

**Refer to Table 6-2, Table 6-3, Table 64 and Table 6-5 on page 68 for technical data and part numbers.

***Fuses are needed only if the power supply has a current rating of more than 10A.

****Refer to section 14.1.3 Supply requirements on page 267 for supply requirements.

Current sharing between drives whose motor outputs are connected in parallel

When used from a 3 phase supply, it is preferable not to link the DC bus because the impedance between DC and each inverter output is just the impedance of the output chokes. Also, on the input side, input current sharing is determined only by making the temperature of the two rectifiers similar and by ensuring that both rectifiers see the same impedance to the line power supply.

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Electrical

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Figure 4-5 Layout for two or more Unidrive SPMD modules operating on a 3-phase AC supply

Onboard

PLC

Advanced

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Te ch n ic a l

Data

Diagnostics

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Unidrive SPM User Guide 29 Issue Number: 3 www.controltechniques.com

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Safety

Master Slave

OTLXXX

Sharing

chokes

OTLXXX

Sharing

chokes

UVW UVW

+DC -DC

Master/ slave

interface

lead

Rectifier to inverter control wiring

Fuses***

Fuses*

INLX1X Line reactor**

24Vdc****

*Refer to Table 6-16, Table 6-17 on page 74 and Table 6-18 on page 75 for technical data and part numbers.

**Refer to Table 6-2, Table 6-3, Table 6-4 and Table 6-5 on page 68 for technical data and part numbers.

***Fuses are needed only if the power supply has a current rating of more than 10A.

****Refer to section 14.1.3 Supply requirements on page 267 for supply requirements.

Current sharing between drives whose motor outputs are connected in parallel

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Figure 4-6 Layout for two Unidrive SPMD modules with a dual SPMC rectifier operating on a 3-phase AC supply

Onboard

PLC

Advanced

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Technical

Data

Diagnostics

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30 Unidrive SPM User Guide

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Slave

OTLXXX

Sharing

chokes

OTLXXX

Sharing

chokes

UVW UVW

+DC -DC

Master/

slave

interface

lead

Rectifier to inverter control wiring

Fuses***

Fuses*

INLX1X Line reactor**

24Vdc****

Slave

*Refer to Table 6-16, Table 6-17 on page 74 and Table 6-18 on page 75 for technical data and part numbers.

**Refer to Table 6-2, Table 6-3, Table 6-4 and Table 6-5 on page 68 for technical data and part numbers.

***Fuses are needed only if the power supply has a current rating of more than 10A.

****Refer to section 14.1.3 Supply requirements on page 267 for supply requirements.

Current sharing between drives whose motor outputs are connected in parallel

To use the remote mounted control master pod, all modules in the system must be slaves. This acts as a master control unit and connects to the system as shown.

The remote mounted control master pod allows the user to place all control circuitry in one low voltage cabinet and permits up to a maximum of 10 Unidrive SPMD modules to be connected in parallel.

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Figure 4-7 Layout for two Unidrive SPMD slave modules with a dual SPMC rectifier operating on a 3-phase AC supply with a remote

mounted control master pod

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Safety

Control master pod Control slave pod

Paralleling cable*

Output from

master to slave

Input from

master to slave

Output from slave to second slave

NOTE

Information

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Parallel control connections

Figure 4-8 Parallel control connections

Installation

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*Only supplied with slave drive.

The parallel cable should be routed according to the rules shown in Figure 6-25 Sensitive signal circuit clearance on page 84 for the control cable.

The screw locks on the parallel cable must be fully tightened.

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WARNING

WAR NING

Information

Introduction

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Mechanical Installation

Electrical

Installation

Getting Star ted

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Running

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Optimization

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Tec h ni c al

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5 Mechanical Installation

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

• Surface and through-panel mounting

• Remote mounting of control master pod

• Enclosure sizing and layout

• Solutions Module installation

• Terminal location and torque settings

• Docking the Unidrive SPMD and SPMC/U

5.1 Safety information

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

Lifting the drive The weights of the drives are as follows:

SPMA 80kg (176.4lb) SPMD 42kg (92.6lb) SPMC/U20kg (44lb)

Use appropriate safeguards when lifting these models.

5.2 Planning the installation

The following considerations must be made when planning the installation:

5.2.1 Access

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

The IP (Ingress Protection) rating of the drive is installation dependent. For further information, please refer to section 5.10 Enclosing drive for high environmental protection on page 56.

5.2.2 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

5.2.3 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, please refer to section 5.8.4 Enclosure sizing on page 51.

5.2.4 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 6 Electrical Installation on page 64.

5.2.5 Fire protection

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

5.2.6 Electromagnetic compatibility

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

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

If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions must be observed. 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 6.13 EMC (Electromagnetic compatibility) on page 79.

5.2.7 Hazardous areas

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

5.3 Terminal cover removal

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

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

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

5.3.1 Removing the terminal covers

Unidrive SPMA and SPMD are fitted with three terminal covers: Control, input and output terminal covers.

Unidrive SPM/C are fitted with two terminal covers: Input and output terminal covers. For the dual SPMC/U rectifier, the terminal covers and housing must be removed to gain access to all the terminals.

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Safety

ControlOutput

Input

SPMA

SPMD

SPMC/U

Control

Output

Input

Output

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Figure 5-1 Location and identification of terminal covers

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34 Unidrive SPM User Guide

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Safety

Pozi Pz2

T25 Torx

Information

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To remove a terminal cover, undo the screw and lift the terminal cover off as shown. When replacing the terminal covers the screws should be tightened with a maximum torque of 1 N m (0.7 lb ft).

Figure 5-2 Removing the terminal covers (Uni SPMA illustrated)

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Figure 5-3 Removing the Unidrive SPMC/U dual rectifier terminal covers and housing

When removing the Unidrive SPMC/U dual rectifier centre housing, undo the 3 x T25 torx head screws as shown in Figure 5-3. When the housing is replaced, the screws should be tightened with a maximum torque of 2.5 N m (1.8 lb ft).

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Safety

1 2

All models

1 2

SPMA and SPMD

NOTE

Single cable entry grommet

Double cable entry grommet

WARNING

NOTE

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

Figure 5-4 Removing the finger-guard break-outs

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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.

Grommets are available for the Unidrive SPM finger-guards. Two versions are available allowing for either single or double cable entries.

These grommets are required to meet IP20 when installed in an open environment.

Figure 5-5 Unidrive SPM finger-guard grommets

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

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

The drive must not be run without the finger guards and grommets installed because In the event of a catastrophic failure, sparks maybe emitted.

The finger guards and grommets must be installed correctly to meet UL.

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WAR NING

Solutions Module

in slot 1

Solutions Module

in slot 2

Solutions Module

in slot 3

NOTE

BAA

NOTE

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5.4 Solutions Module installation/removal

Power down the drive before installing / removing the Solutions Module.

Figure 5-6 Installation and removal of a Solutions Module

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

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

Figure 5-7 Installation and removal of a keypad

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

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

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

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

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

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5.5 Mounting of control master/slave pod

5.5.1 Mounting the control master/slave pod on the

drive

For control master/slave pod paralleling connections, refer to section

Parallel control connections on page 32.

Figure 5-8 Mounting the control master pod on the drive

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Figure 5-9 Mounting the control slave pod on the drive

UL Listing

Information

1. In order to expose the top mounting hole, the terminal covers need

to be removed. This is done by undoing the terminal cover screw highlighted and then removing the two plastic covers.

2. Care must be taken when installing master control pod. Refer to

Figure 5-10. Use the 2 x M6 screws to mount the control master pod to the drive in the position shown.

3. The terminal covers can then be re-installed.

1. In order to expose the mounting holes, remove the control slave pod cover. This is done by undoing the screws highlighted and pulling the cover off.

2. Care must be taken when installing control slave pod. Refer to Figure 5-10. Use the 2 x M6 screws to mount the control slave pod to the drive in the position shown.

3. The cover can then be re-installed.

Figure 5-10 Control master/slave pod and power module base

plate connectors

Ensure that the connector on the back of the control master/slave pod (1) is securely fitted to the power module metal base plate connector (2).

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Safety

111.6mm (4.39in)

59.9mm (2.36in)

35.4mm (1.39in)

449.4mm (17.69in)

160.4mm (6.31in)

390.2mm

(15.36in)

∅

5.5mm

(0.22in)

Te rm i na l cover screw

Mounting

holes

CAUTION

NOTE

SPM interface bracket

SPM inverter to rectifier

busbars

Information

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5.5.2 Remote mounting control master pod

Figure 5-11 Control master pod dimensions

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The control master pod can be mounted remotely.

In order to meet IP20, the control master pod should be mounted to a solid surface to restrict access to the back of the module.

In order to expose the top mounting hole, the terminal covers need to be removed. This is done by undoing the terminal cover screw highlighted in Figure 5-11, and then removing the two plastic covers.

Use 2 x M6 screws to mount the control master pod to pre-drilled holes using the dimensions shown in Figure 5-11.

The parallel cable for the control master pod is 2m long, as such it should be mounted close to the appropriate power module.

5.6 Docking a Unidrive SPMC/U to an SPMD

Docking a Unidrive SPMC/U to an SPMD allows the user to create an AC input/AC output drive. The advantages of docking are:

• Optimization of enclosure layout

• Reduced cabling

Docking results in a reduction of heatsink air flow which has an effect on the drive rating. Refer to section 14.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 263.

5.6.1 Installing the docking kit

When mounting an SPMD and SPMC/U in a vertical plane, as shown in Figure 5-17 on page 43 and Figure 5-21 on page 46, the following

docking kit (3470-0012) can be used to electrically connect the two modules together.

Figure 5-12 Docking kit

The SPM interface bracket should be connected first, followed by the SPM inverter to rectifier busbars, to the appropriate terminals as shown in Figure 5-13.

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Safety

Top o f

SPMD

(inverter)

Bottom of

SPMC/U

(rectifier)

SPM interface bracket

busbar

+DC

busbar

-DC

busbar

NOTE

Information

Figure 5-13

Introduction

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Electrical

Installation

Location of the docking kit when installed

Getting

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parameters

A current derating must be applied to the Unidrive SPMD1404 when docked with the Unidrive SPMC/U. Details can be found insection

14.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 263.

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40 Unidrive SPM User Guide

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Safety

WAR NING

310mm (12.205in)

18.9mm (0.744in)

1131mm

(44.528in)

298mm (11.732in)

1168.8mm (46.016in)

25.7 0.5mm

(1.012 0.020in)

258.6 0.5mm

(10.181 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

1150.8 ±0.5mm

(45.307 0.020in)

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5.7 Mounting methods

Unidrive SPMA, SPMD and SPMC can be either surface or throughpanel mounted using the appropriate brackets.

Surface mounting is where the drive is simply secured to the enclosure wall/backplate.

Through-panel mounting is where the drive is secured with the heatsink protruding through the enclosure panel to the external environment. This has the effect of reducing the temperature within the enclosure.

Figure 5-14 Surface mounting the Unidrive SPMA

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

5.7.1 Surface mounting

Lifting the drive The weights of the drives are as follows:

SPMA 80kg (176.4lb) SPMD 42kg (92.6lb) SPMC/U20kg (44lb)

Use appropriate safeguards when lifting these models.

Unidrive SPM User Guide 41 Issue Number: 3 www.controltechniques.com

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Safety

310mm (12.205in)

18.9mm (0.744in)

758.7mm

29.870in

18.9mm (0.744in)

298mm (11.732in)

795.5mm

(31.319in)

258.6 ±0.5mm

(10.181 ±0.020in)

25.7 0.5mm (1.012 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

777.5 ±0.5mm

(30.650 ±0.020in)

310.1mm (12.209in)

18.3mm (0.720in)

386.4mm (15.213in)

297.4mm (11.709in)

399.1mm

(15.713in)

25.7 0.5mm (1.012 0.020in)

∅

8.5mm

(0.335in)

258.6 0.5mm

(10.181 0.020in)

145.3 0.25mm

(5.720 0.010in)

± ±

90.3 0.25mm

(3.555 0.010in)

380.5 ±0.5mm

(14.980 ±0.020in)

Information

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Installation

Figure 5-15 Surface mounting the Unidrive SPMD

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Figure 5-16 Surface mounting the Unidrive SPMC/U (rectifier)

42 Unidrive SPM User Guide

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Safety

310.1mm (12.209in)

18.3mm (0.720in)

114 5.1 mm

(45.083in)

297.4mm (11.709in)

1145.1mm

(45.083in)

25.7 0.5mm (1.012 0.020in)

∅

8.5mm

(0.335in)

258.6 0.5mm

(10.181 0.020in)

258.6 0.5mm

(10.181 0.020in)

145.3 0.25mm

(5.720 0.010in)

90.3

0.25mm

(3.555

0.010in)

380.5 0.25mm

(14.980 0.010in)

± ±

777.3 0.25mm

(30.602 0.010in)

± ±

1163.8 0.5mm

(45.819 0.020in)

∅

8.5mm

(0.335in)

NOTE

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Figure 5-17 Surface mounting the Unidrive SPMD with SPMC/U (rectifier) and docking kit

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A current derating must be applied to the Unidrive SPMD1404 when docked with the Unidrive SPMC/U. Details can be found in section

14.1.1 Power and current ratings (Derating for switching frequency and

temperature) on page 263.

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Safety

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

1105.6mm (43.528in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

1131mm

(44.528in)

1179.3mm (46.429in)

98mm

(3.858in)

298mm (11.732in)

258.6 0.5mm

(10.181 0.020in)

286.0 0.5mm

(11.260 0.020in)

± ±

1107.8 0.5mm

(43.614 0.020in)

27.1 0.5mm

(1.067 0.020in)

13.7±±0.5mm

(0.539 0.020in)

258.6 0.5mm

(10.181 0.020in)

1161.2

0.5mm

(45.717

0.020in)

R6.5mm

(0.256in)

R6.5mm

(0.256in)

Information

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5.7.2 Through-panel mounting

Figure 5-18 Through-panel mounting the Unidrive SPMA

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44 Unidrive SPM User Guide

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Safety

310.1mm (12.209in)

758.7mm

(29.870in)

806.9mm (31.768in)

202mm (7.953in)

95mm

(3.740in)

297mm (11.693in)

732.0mm

(28.819in)

R6.5mm

(0.256in)

27.1 0.5mm

(1.067 0.020in)

286.0 0.5mm

(11.260 0.020in)

± ±

258.6 0.5mm

(10.181 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

R6.5mm

(0.256in)

13.7±±0.25mm

(0.539 0.010in)

735.0

(28.937 )

±0.5mm

±0.020in

258.6 0.5mm

(10.181 0.020in)

789.2

0.5mm

(31.071

0.020in)

310.1mm (12.209in)

25.1mm (0.988in)

386.4mm (15.213in)

198.3mm (7.807in)

95.7mm

(3.768in)

297.0mm (11.693in)

341.9mm

(13.461in)

27.5 0.5mm

(1.08 0.020in)

3±

R6.5mm

(0.256in)

258.6 0.5mm

(10.181 0.020in)

286.0 0.5mm

(11.260 0.020in)

345.9 0.5mm

(13.618 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

R6.5mm

(0.256in)

145.3 0.25mm (5.720 0.010in)

113.3 0.25mm

(4.461 0.010in)

13.7±±0.5mm

(0.539 0.020in)

387.2

±0.5mm

(15.244

±0.020in)

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Figure 5-19 Through-panel mounting the Unidrive SPMD

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Figure 5-20 Through-panel mounting the Unidrive SPMC/U (rectifier)

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Safety

310.1mm (12.209in)

24.0mm (0.945in)

25.1mm (0.988in)

1145.1mm (45.083in)

1194.1mm

(47.012in)

198.3mm (7.807in)

96.7mm

(3.807in)

297mm (11.693in)

341.9mm

(13.461in)

731.9mm

(28.815in)

1118.2mm

(44.024in)

∅

8.5mm

(0.335in)

286.0 0.5mm

(11.260 0.020in)

± ±

258.6 0.5mm

(10.181 0.020in)

27.5±0.25mm

(1.083±0.010in)

345.9±0.5mm

(13.618±0.020in)

R6.5mm

(0.256in)

145.3 0.25mm (5.720 0.010in)

∅

8.5mm

(0.335in)

735.0± 8±

0.5mm

( 8.937 0.020in)

13.7±±0.25mm

(0.539 0.010in)

387.1±±0.5mm

(15.240 0.020in)

17.5±±0.25mm

(0.689 0.010in)

789.2±

0.5mm

(31.071 0.020in)

112 1. 8

±±1.0mm

(44.165

0.040in)

NOTE

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Figure 5-21 Through-panel mounting the Unidrive SPMD with SPMC/U (rectifier) and docking kit

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A current derating must be applied to the Unidrive SPMD when docked with the Unidrive SPMC/U. Details can be found insection 14.1.1 Power

and current ratings (Derating for switching frequency and temperature) on page 263.

46 Unidrive SPM User Guide

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Safety

Short section

Long section

Short section

Long section

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5.7.3 Mounting brackets

Table 5-1 Mounting brackets

Model

size

SPMA

Surface Through-panel

Hole

size

8.5mm

(0.335in)

SPMD

8.5mm

(0.335in)

SPMC

8.5mm

(0.335in)

5.7.4 Installation of the Unidrive SPM mounting brackets

Common

The Unidrive SPM range use the same mounting brackets for surface and through-panel mounting.

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

Figure 5-22 Unidrive SPM mounting bracket

Drive specific brackets

Unidrive SPMA

Unidrive SPMA also requires two top mounting brackets when the drive is surface mounted. The two brackets should be installed to the top of the drive as shown in Figure 5-24.

Figure 5-24 Location of top Unidrive SPMA surface mounting brackets

Unidrive SPMC and SPMU Figure 5-25 Installation of the Unidrive SPMC/U surface mounting

brackets

The mounting bracket must be installed in the correct orientation with the long section inserted into or attached to the drive and the short section is attached to the back plate. Figure 5-23 shows the orientation of the mounting bracket when the drive is surface and through-panel mounted.

Figure 5-23 Orientation of the Unidrive SPM mounting bracket

When through-panel mounted, the mounting brackets on the left hand side of the Unidrive SPMA and SPMD can be secured using the screws already located there. This only applies to the bottom of the Unidrive SPMC/U rectifier.

On the right hand side, the mounting brackets are just inserted into the slots in the chassis of the drive; no mounting screws are present here.

1. Common Unidrive SPM mounting bracket. Ensure short section attached to backplate

2. Unidrive SPMC/U supply ground bracket. M10x20 screw required to mount bracket, maximum length 40mm (1.575in) used with vibration resistant washer. Torque setting of 15 N m (11.1 lb.ft)

3. Unidrive SPMC/U motor ground bracket

4. Unidrive SPMC/U surface mounting bracket. M8 screws required to mount bracket, minimum length 20mm (0.787in) used with vibration resistant washer. Torque setting of 9 N m (6.6 lb.ft)

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Figure 5-26 Installation of the Unidrive SPMC/U through panel

mounting brackets

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1. Common Unidrive SPM mounting bracket. Ensure short section attached to backplate

2. Unidrive SPMC/U supply ground bracket. M10x20 screw required to mount bracket, maximum length 40mm (1.575in) used with vibration resistant washer. Torque setting of 15 N m (11.1 lb.ft)

3. Unidrive SPMC/U motor ground bracket

48 Unidrive SPM User Guide

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Safety

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

Note

For EMC compliance:

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

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

SPMA:

SPMD: 60mm (2.362in)

Docked SPMD and SPMC: 60mm (2.362in)

30mm (1.181in)

≥ ≥

≥

Optional braking

resistor and overload

AC supply

contactor and

fuses or MCB

Locate as required

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

External

controller

Signal cables

Plan for all signal cables

to be routed at least 300mm (12in) from the drive and any power cable

Fan supply: 24Vdc

SPMA: 3.3A

SPMD1401 & 1402: 6.3A

SPMD1403 & 1404: 7.6A

Enclosure

≥

100mm

(4in)

≥

100mm

(4in)

Optional external

EMC filter

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5.8 Enclosure

5.8.1 Enclosure layout

Observe the clearances in Figure 5-3 taking into account any appropriate notes for other devices / auxiliary equipment when planning the installation. A Unidrive SPMA is shown, but the illustration also applies to a docked Unidrive SPMD and SPMC.

Figure 5-27 Enclosure layout

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Safety

Note

For EMC compliance:

1) When using an external EMC

filter, one filter is required for

each drive

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

A≥60mm (2.362in)

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

External

controller

Signal cables

Plan for all signal cables

to be routed at least 300mm (12in) from the drive and any power cable

Enclosure

≥

100mm

(4in)

AC supply

contactor and

fuses or MCB

Locate as required

The Unidrive

SPMC must not be mounted any higher than

the SPMD

The Unidrive SPMC

can be mounted

upside down (e.g.

for easier wire

routing) if required

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

Fan supply: 24Vdc

SPMA: 3.3A

SPMD1401 & 1402: 6.3A

SPMD1403 & 1404: 7.6A

Optional external

EMC filter

≥

100mm

(4in)

NOTE

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Figure 5-28 Alternative enclosure layout: Undocked Unidrive SPMD and SPMC

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The Unidrive SPMC must not be mounted any higher than the SPMD. This is to prevent the heated air expelled from the Unidrive SPMD being

recirculated through the SPMC.

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Safety

0.95

0.9

0.85

0.8

0.75

Derate factor (Df)

0 500 1000 1500 2000 2500 3000

Altitude (m)

1.02

1.015

1.01

1.005

0.995

Correction factor (Cf)

20 22 24 26 28 30 32 34 36 38

Temperature ( C)

1.035

1.03

1.025

NOTE

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5.8.2 Enclosure 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

rate

) which

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

= T

rate

+ 5°C

int

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

= T

rate

int

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

= the greater of T

rate

+5°C, or T

ext

int

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

= 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 14 Technical D a ta .

5.8.3 Altitude derating

Multiply the maximum rated output current by the derate factor (Df) in Figure 5-29 and the ambient correction factor (Cf) in Figure 5-30.

Rated output current = Df x Cf x Oc

Figure 5-29 Altitude derate factor

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over rated. The maximum permissible output currents should remain the same as those given at 40°C.

• If the drive is required to operate above 40°C the derates at 50°C

should be applied. Refer to section 14.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 263

• The same applies for altitude below 1000m. There should be no over rating at lower altitude

For applications over 3000m, contact the supplier of the drive.

5.8.4 Enclosure sizing

This section looks at a method for cooling a medium power density enclosure. By running through a worked example it brings out the issues associated with cooling the drives when they are completely mounted inside an enclosure.

This example only considers one possible method of enclosing the drives and tries to highlight and solve thermal issues created by hot air recirculating inside an enclosure. Other methods of enclosure design are also possible, such as through panel mounting, which removes many of the issues discussed in this chapter. Refer to section 5.7.2 Through- panel mounting on page 44.

The enclosure design example will use the following conditions:

• Enclosure placed in a room with a 30°C ambient and an altitude <1000m

• Continuous output current requirement from the system = 650A

Parts used in system model:

• 1800mm (70.87in) x 800mm (31.5in) x 500mm (19.69in) enclosure with input and output ventilation

• 2 x SPMD1404

• 2 x docking SPMC1402

• 2 x input line reactors (L1)

• 2 x output sharing chokes (L2)

Figure 5-30 Ambient temperature correction factor

Note:

• The ambient temperature correction factor used is for altitude

calculation only. If the ambient is less than 40°C the drive cannot be

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Safety

L1 L1

Recirculated

air

Input air flow

Output air flow

Enclosure vent

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Figure 5-31 Enclosure design example

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Enclosure design to prevent recirculation of hot air

Figure 5-32 Recommended enclosure design

Drive selection

Select drives necessary to achieve desired output current based on altitude calculation and other drive derates (e.g. paralleling derates, switching frequency derates, ambient derate etc).

For front view of enclosure, refer to Figure 5-31. Spacing between units and sides of enclosure: >60mm

52 Unidrive SPM User Guide

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Open area of venting %

Open area of roof + open area of inlet x 100

2 x cubicle width x cubicle depth

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

0.8

0.6

0.4

0.2

Recirculation factor

0 20406080100120

Open area (%)

1.2

NOTE

Open area of venting %

Open area of roof + open area of inlet x 100

2 x cubicle width x cubicle depth

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

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Calculation of temperature rise in enclosure

Inputs

Table 5-2 Example data

Output sharing choke loss under single unit (L2) 250W Total loss of single drive (Uni SPMC + SPMD) 4290W Number of drives in enclosure 2 Width of enclosure 0.8m Depth of enclosure 0.5m

Open area of roof vent (outlet)

Open area of inlet vent External ambient 30°C

Altitude derate factor (Cf x Df) 1

For this example it is assumed the drive is in an altitude below 1000m and the enclosure it is mounted in has input and output ventilation.

Calculate open area % of venting and recirculation factor

= (0.27 + 0.15) x 100 / (2 x 0.8 x 0.5)

= 52.5%

From Figure 5-33 the re-circulation factor = 0.76.

Figure 5-33 Recirculation factor

0.27m

0.15m

Calculate temperature rise

Table 5-3 Unidrive SPM air flow rates

Modules Flow rate (m3/hr)

SPMA (All) 250 SPMD 1201 to 1204, SPMD1401/2,

SPMD1601/2 SPMD1403/4, SPMD 1603/4 305 SPMC/U 200

Calculating temperature rise in enclosure

dT = 3kPr/V

Where:

V = Airflow in m

/hr (Unidrive SPMD1404 flow rate = 305)

dT = Temperature rise Pr = Loss affecting drive temp k = 1 / Altitude de-rate

Therefore ambient temperature rise (dT):

= (3 x 1 x 3510.4) / 305 = 34.5°C

So,

Ambient temperature inside enclosure = External ambient + temperature rise = 64.5°C

This shows that with a maximum allowable drive ambient temperature of 40°C, the enclosure will get 24.5°C too hot.

Processing results

Option 1: If the absolute temperature inside the enclosure is still less

than 50°C, select a drive with the correct rating at 50°C. Option 2: Add more venting, if possible, to reduce the recirculation and

recalculate.

Option 3: Add enclosure fan. Option 4: Redesign the enclosure so that the drives can be through

panel mounted. This means that most of the heat can escape outside the main enclosure and the input air into the heat sinks will remain at the external ambient and not be affected by recirculation. Refer to section

5.7.2 Through-panel mounting on page 44.

250

This is an approximation to the amount of air that is re-circulated within the enclosure due to inlet and outlet venting restrictions. The factor has a safety factor built in to it to ensure a safe result. The factor has been calculated using CFD software, testing the amount of heat flow back into the drive when different vent restrictions are given. The factor can also be applied to an SPMA and separated SPMD.

Calculate loss which affects the drive inlet air temperature

Loss affecting drive temperature (Pr) = Lower choke Loss (Pc) + (Total loss of single drive (Dp) x Recirculation factor (Rf))

= 250 + (4290 x 0.76)

= 3510 W

This is the loss from 1 drive unit only as simulations have shown that with drives mounted inline and in a symmetric system the losses are shared equally.

Unidrive SPM User Guide 53 Issue Number: 3 www.controltechniques.com

Heat loss through the front of the drive still needs to be considered.

Adding enclosure fan

Calculate required flow rate

• Fan needs to remove the effect of re-circulation and the added choke loss.

• Loss effecting drive temp (Pr) = 3510.4W

• The above Loss of 3510.4W is for one drive only, so with an enclosure of 2 units the total loss to remove = 7020.8W

Calculate the temperature rise allowed in the enclosure:

Temperature rise (dT) = (Allowable drive ambient - 5 {safety

= (40 - 5) - 30 = 5°C

Then using:

V = 3kPr/ (dT)

Flow rate required to remove loss = (3x1x7020.8) / 5

= 4212.5 m

Calculate back pressure on fan

factor}) - External ambient

/hr

Page 54

Safety

250

200

150

100

Pressure drop (Pa)

0 20406080

Total open area (%)

100

400

350

300

500

450

Information

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Figure 5-34 Pressure drop

Best practice: Size the enclosure air inlet and exit vents at least as

large as the venturi opening of the fan used. This will ensure a negligible back pressure.

With 52.5% open area: Pressure drop = 34

Selecting fan

Considerations when selecting fan:

• Dimensions and space limitation

• Required flow rate

• Static pressure

•Noise level

• Power supply

Table 5-4 Type of fan

Backward curved Blower (Centrifugal)

• Outward flow perpendicular to inward flow

• Good at high + low back pressures

• Good resistance to dust and dirt due to impeller design

• Do not need cowling

• Relatively small diameters required for high airflow

Forward curved blower (Centrifugal)

• Requires cowling

• Good at directing flow

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Figure 5-35 AC supply 400mm diameter blower performance

Final summary

1. Enclosure fans can be placed on inlet and outlet depending on system limitations.

2. Considerations with fan on outlet:

• Higher Ambient temperature surrounding fan, can affect fan life.

• Depressurisation of enclosure which may draw in dust through

any apertures.

3. Considerations with fan on inlet:

• Proximity of dust filter to fan, can create excess back pressure

on fan

• Non-uniform flow across internal components

4. Dust filters: Use the largest filter possible, in order to:

a. Increase dust capacity b. Reduce pressure drop

5. Make sure Drive inlets are as close to the enclosure air inlet as possible

6. Do not block the inlet and outlets of the drive airflow. Keep to best practice spacing between drives and other parts in enclosure.

7. Beware of blocking air inlets or outlets with cable routing.

5.9 Heatsink fan operation

Axial Fan

• Not good at high pressure but good for low pressure applications such as room venting and ducting

• Inward flow and outward flow is in same direction

• Good in straight line duct applications.

• Large diameters required for high air flows

Fan curves

Once the type of fan has been selected the next step is to match the system characteristics of your enclosure to the fan performance curve.

System operating point is:

Static pressure = 34 Pa

Flow rate= 4212.5 m

/hr

Selected fan is a Backward curved centrifugal blower to place in the roof and take advantage of the perpendicular flow and high flow rate properties.

54 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

The Unidrive SPMA, SPMD and SPMC/U are ventilated by a heatsink mounted fan and an auxiliary fan to ventilate the drive box. The fan housing forms a baffle plate, channelling the air through the heatsink chamber. Thus, regardless of mounting method (surface mounting or through-panel mounting), the installation of additional baffle plates is not required.

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

The heatsink fan on Unidrive SPMA, SPMD and SPMC/U is variable speed. 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 Unidrive SPMA and SPMD are also installed with variable speed fan to ventilate the capacitor bank.

All Unidrive SPM models require an external 24Vdc supply to drive the fans. See section 6-12 Location of the heatsink fan supply connections (SPMA & SPMD) on page 73 for more information.

To avoid premature failure, regular cleaning on the fan is recommended as outlined in Table 5-8 on page 58. See the following diagrams which demonstrate how to remove the fan from the drive.

Page 55

Safety

Fan cassette screws

Fan connector

Fan connector (removed)

Fan cassette

Fan screws

NOTE

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Figure 5-36 Removal of Unidrive SPMA/D fan (part 1) Figure 5-37 Removal of Unidrive SPMA/D fan (part 2)

UL Listing

Information

1. Remove the cable from the fan connector

2. Undo fan cassette screws

3. Slide fan cassette out of heatsink chamber

4. Remove fan screws in order to remove fan from cassette

Figure 5-38 Removal of Unidrive SPMC/U fan

The following rectifiers only have one fan included in their assembly:

SPMU1402 SPMC/U1601

Table 5-5 Unidrive SPM fan assembly part numbers

SPMA, SPMD14X1, SPMD14X2, SPMD16X1, SPMD16X2 9701-0019 SPMD14X3, SPMD14X4, SPMD16X3, SPMD16X4 9701-0020

Model Fan assembly

SPMC1402, SPMC/U2402, SPMC/U2601 9701-0021 SPMU1402, SPMC/U1601 9701-0022

Unidrive SPM User Guide 55 Issue Number: 3 www.controltechniques.com

Page 56

Safety

IP20

(NEMA1)

IP54 (NEMA 12)

enclosure

Drive fitted with IP54 fan as standard

Gasket seal

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5.10 Enclosing drive for high environmental protection

An explanation of IP Rating is provided in section 14.1.10 IP Rating (Ingress Protection) on page 267.

The standard drive is rated to IP20 pollution degree 2 (dry, nonconductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP54 rating (NEMA 12) at the rear of the heatsink for through-panel mounting.

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

Figure 5-39 Example of IP54 (NEMA 12) through-panel layout

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The main gasket should be installed as shown in Figure 5-39. Any screws / bolts that are used for mounting should be installed with the nylon washers provided in the kit box to maintain a seal around the screw hole. See Figure 5-40.

56 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Page 57

Safety

50mm max

(1.97in max)

5mm

(0.2in)

253mm

(9.96in) placed centrally along length

817mm

(32.17in)

5mm

(0.2in)

817mm (32.17in)

Backplate

Enclosure

rear wall

456

4 3

Information

Introduction

It may be necessary to improve the rigidity of the through panel

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1. Use a thicker panel for the mounting wall of the enclosure through mounting surface due to the larger distance between the top and bottom mounting brackets and the need to maintain compression on the gasket.

2. Use an internal backplate to pull the rear wall of the enclosure up to When the drive is mounted, if the gap between the drive flange (which

the gasket rests on) and the rear wall of the enclosure is ≥6mm at any point around the drive then the following methods can be used to compress the gasket further:

3. If an internal backplate is not available a separate clamp can be

Figure 5-40 Option 2 for achieving IP54 (NEMA 12) through-panel mounting

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which the drive is mounted.

the drive gasket. See Figure 5-40 for details. (Nylon washers are supplied in the standard drive kit for sealing off any nut and bolt mountings that exit through the rear wall of the panel).

used to simulate option 2. See Figure 5-41 on page 58. 4 off sealing clamps are supplied in the drive kit box.

Table 5-6 Description of fixings Table 5-7 Quantity of nylon washers included in the kit boxes

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

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

Unidrive SPM User Guide 57 Issue Number: 3 www.controltechniques.com

Page 58

Safety

36.5mm (1.44in)

253mm (9.96in) placed centrally

along length

Enclosure rear wall

Sealing bracket (4 places)

NOTE

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Figure 5-41 Option 3 for achieving IP54 (NEMA 12) through panel mounting

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The heatsink fan installed on the Unidrive SPMC/U is IP21 rated as standard. To achieve IP54 rating (NEMA 12) at the rear of the heatsink for through panel mounting, the SPMC/U heatsink fan must be changed for the IP54 version, part number 3251-7824.

The procedures in section 5.9 Heatsink fan operation on page 54 should be followed to change the fan.

If the standard fan is used in a dirty/dusty environment, reduced fan lifetime will result. Regular cleaning of the fan and heatsink is recommended in this environment. The heatsink fan installed in Unidrive SPMA and SPMD are IP54 rated as standard.

The guidelines in Table 5-8 should be followed.

Table 5-8 Environment considerations

Environment Fan Comments

Clean Standard Dry, dusty (non-

conductive) Dry, dusty

(conductive)

Standard

Standard / IP54

Regular cleaning recommended. Fan lifetime may be reduced.

IP54 compliance IP54 Regular cleaning recommended.

When designing an IP54 (NEMA 12) enclosure (Figure 5-39), consideration should be given to the dissipation from the front of the drive.

Table 5-9 Power losses from the front of the drive when through-

panel mounted

Model Power loss

SPMA ≤480W SPMD ≤300W SPMC ≤50W SPMU ≤50W

5.11 External EMC filter

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

Table 5-10 Single drive EMC filter details

Drive

SPMA14X1 to

SPMA14X2

SPMA16X1 to

SPMA16X2

SPMD12X1 to

SPMD12X4

SPMD14X1 to

SPMD14X4

SPMD16X1 to

SPMD16X4

The external EMC filters for Unidrive SPMA and SPMD are designed to be mounted above the drive, as shown in Figure 5-42.

Mount the external EMC filter following the guidelines in section

6.13.5 Compliance with generic emission standards on page 84.

Figure 5-42 Mounting the external EMC filter

Schaffner Epcos

CT part no. Weight CT part no. Weight

4200-6603

4200-6604

4200-6315

4200-6316

5.25 kg

(11.6 lb)

5.25 kg

(11.6 lb)

5.5 kg

(12.11 Ib)

5.5 kg

(12.11 Ib)

5.5 kg

(12.11 Ib)

4200-6601

4200-6602

4200-6313

4200-6314

8.6 kg

(19.1 Ib)

8.6 kg

(19.1 Ib)

8.6 kg

(19.1 Ib)

8.6 kg

(19.1 Ib)

8.5 kg

(18.7 Ib)

58 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Page 59

Safety

V: Ground stud: M10 Z: Hole size: 10.5mmÆ

Information

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configuration

Figure 5-43 External EMC filter

Mechanical Installation

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Installation

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Table 5-11 Optional external EMC filter details

38 mm

(1.496 in)

43 mm

(1.700 in)

40 mm

(1.574 in)

42 mm

(1.654 in)

43 mm

(1.700 in)

136 mm

(5.354 in)

147 mm

(5.787 in)

149 mm

(5.866 in)

66 mm

(2.600 in)

128 mm

(5.040 in)

76 mm

(3.000 in)

73 mm

(2.874 in)

127 mm

(5.000 in)

76 mm

(3.000 in)

53.5 mm (2.106 in)

60 mm

(2.362 in)

53.5 mm (2.106 in)

60 mm

(2.362 in)

295 mm

(11.614 in)

357 mm

(14.055 in)

339 mm

(13.346 in)

364 mm

(14.330 in)

339 mm

(13.346 in)

25Nm

(18.4

Ib ft)

10Nm

(7.4

Ib ft)

CT part no.

4200-6603

4200-6604

4200-6315

4200-6316

4200-6601 4200-6602 4200-6313 4200-6314

Manufacturer

ABCDEFGH I J WV

191 mm

(7.520 in)

Schaffner

Epcos

220 mm

(8.661 in)

226 mm

(8.900 in)

191 mm

(7.520 in)

220 mm

(8.661 in)

140 mm

(5.512 in)

170 mm

(6.700 in)

140 mm

(5.512 in)

170 mm

(6.700 in)

110 mm

(4.330 in)

230 mm

(9.055 in)

210 mm

(8.268 in)

2 mm

(0.079 in)

Unidrive SPM User Guide 59 Issue Number: 3 www.controltechniques.com

Page 60

Safety

EFHGGCZ

V: Ground stud - 4200-6801: M10, 4200-6802/03: M12

Z: 11mm,

Y: 12mm

4200-6801: 4200-6802/03: 14mm

∅

∅∅

Information

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The following EMC filters are available for multiple module drives.

Table 5-12 EMC filters for multiple drive combinations

Combination

CT part no. Weight

Epcos

2 x SPMD1401

4200-6801 22kg (48.5lb)2 x SPMD1402 2 x SPMD1403 2 x SPMD1404 4 x SPMD1401 3 x SPMD1403

4200-6802 28kg (61.7lb)

4 x SPMD1402 4 x SPMD1403 4 x SPMD1404

4200-6803 34kg (75lb)

Figure 5-44 Multiple drive EMC filters

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Table 5-13 Optional external EMC filter details

CT part no.

4200-6801

4200-6802

4200-6803

Manufacturer

Epcos

ABCD E FGHW V

350mm

(13.78in)

400mm

(15.75in)

145±0.5mm

(5.71±0.02in)

170±0.5mm

(6.71±0.02in)

60mm

(2.36in)

80mm

(3.15in)

260mm

(10.24in)

300mm

(11.81in)

235±1mm

(9.2±0.04 in)

275±1mm

(10.83±0.04in)

2mm

(0.08in)

2.5mm (0.1in)

42±3mm

(1.65±0.12in)

52±3mm

(2.05±0.12in)

92±3mm

(3.62±0.12in)

116 mm

(4.57in)

166mm (6.54in)

440±2.5mm

(17.32±0.1in)

460±2.5mm

(18.11±0.1in)

590±3mm

(23.23±0.12in)

10 N m

(7.4 lb ft)

15.5 N m

(11.4 lb ft)

60 Unidrive SPM User Guide

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Page 61

Safety

187mm (7.36in)

∅

130mm (5.12in)

5mm (0.2in)

227±1mm (8.94 0.04in)±

8.5

0.5mm (0.34

0.02in)

5mm (0.2in)

155 1mm (6.1 0.04in)

222 1mm (8.74 0.04in)±±

142 1mm (5.59 0.04in)±±

108 1mm

(4.25 0.04in)

7.5mm (0.3in)

8.5 0.5mm

(0.17 0.02in)

± ±

10mm

(0.39in)

80mm (3.15in)

5mm

(0.2in)

222mm (8.74in)

110 mm (4.33in)

155mm

(6.1in)

30mm (1.18)in

15±1mm

(0.59 0.04in)±

∅

8.5mm

(0.34in)

75.5 2mm

(2.97 0.08in)

335 5mm

(13.19 0.2in)

335 5mm

(13.19 0.2in)

265 5mm

(10.43

0.2in)

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5.12 Line reactor mounting dimensions

5.12.1 Input line reactors

Figure 5-45 Single input line reactor (INLX0X)

Figure 5-46 Dual input line reactor (INLX1X)

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5.12.2 Output sharing chokes

Figure 5-48 Single output sharing choke (OTLX0X)

Figure 5-49 Dual output sharing choke (OTLX1X)

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Figure 5-47 Single line input reactor force cooled (INLX0XW)

For overall dimensions and other details, refer to section 6.3 Output sharing choke specification on page 69.

For overall dimensions and other details, refer to section 6.2.2 Input line reactor specifications on page 67.

Unidrive SPM User Guide 61 Issue Number: 3 www.controltechniques.com

Page 62

Safety

Master interface

SPMA SPMD SPMC/U

Relay terminals

3mm

Control terminals

2.5mm

8mm AF

M10 nut 17mm AF

2.5mm

M10 nut 17mm AF

2.5mm

M10 nut 17mm AF

2.5mm

11m m Suitable for M10 nut & bolt

AC IN

DC IN

AC IN

AC OUT AC OUT DC OUT

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5.13 Electrical terminals

5.13.1 Location of the power and ground terminals

Figure 5-50 Locations of the power and ground terminals on Unidrive SPM

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62 Unidrive SPM User Guide

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Page 63

Safety

WAR NING

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Installation

5.13.2 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 5-14 Master/slave control and relay terminal data

Model Connection type Torque setting

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

Table 5-15 Drive power terminal data

Model AC terminals

All

High current DC

and braking

M10 stud

15 N m

Torque tolerance ±10%

Table 5-16 Optional external EMC Filter terminal data

Power

CT part

number

Manufacturer

connections

Max torque

4200-6603 4200-6604 4200-6315

Schaffner

12 N m

(8.8 lb ft)

4200-6316 4200-6601 4200-6602 4200-6313 4200-6314 4200-6801

Epcos

10 N m

(7.4 lb ft)

4200-6802 4200-6803

Ground terminal

M10 stud or nut

and bolt

15 N m

Ground connections

Ground

stud size

M10

M12

Getting Star ted

Max

torque

25 N m

(18.4 lb ft)

10 N m

(7.4 lb ft)

15.5 N m

(11.4 lb ft)

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5.14 Routine maintenance

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

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

Environment

Ambient temperature

Dust

Moisture

Enclosure

Enclosure door filters

Electrical

Screw connections Ensure all screw terminals remain tight

Crimp terminals

Cables Check all cables for signs of damage

Ensure the enclosure temperature remains at or below maximum specified

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

Ensure the drive enclosure shows no signs of condensation

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

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

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Safety

WARNING

CAUTION

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6 Electrical Installation

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

• SAFE TORQUE OFF (SECURE DISABLE) function

• Internal EMC filter

• EMC compliance with shielding / grounding accessories

• Product rating, fusing and cabling information

• Brake resistor details (selection / ratings)

Electric shock risk

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

• AC supply cables and connections

• DC and brake cables, and connections

• Output cables and connections

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

Isolation device

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

STOP function

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

Use of rectifiers other than Unidrive SPMC/U

If a rectifier other than Unidrive SPMC/U is used with Unidrive SPMD, then it must be installed with line to ground varistors which are capable of reducing overvoltage transients from category III to values of category II. (ref. EN61800-5-2). This is to ensure L-E transients do not exceed 4kV because there are no varistors installed in a D module and the insulation system from power to ground is designed to category II.

Use of rectifiers other than Unidrive SPMC/U

Any non Control Techniques rectifier must be installed with AC line fuses that correspond to those specified for the Unidrive SPMC/U. If this is not possible then DC fuses should be specified for the Unidrive SPMD. This is to ensure validity of the safety testing carried out to complete the safety file and for UL certification, especially in the event of a short circuit bus cap in the DC bus.

0V control connections on both SPMA and SPMD drives are internally earthed and cannot be disconnected. Ensure that there is adequate equipotential bonding between parts of a system with interconnected control wiring.

The power supply to all modules in a multi-module system should be applied at the same time, to ensure the drive powers-up correctly. Otherwise the drive may power-up with a hardware fault (HF) trip code.

SAFE TORQUE OFF (SECURE DISABLE) function

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

Stored charge

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

Equipment supplied by plug and socket

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

Permanent magnet motors

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

64 Unidrive SPM User Guide

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Page 65

SPMA

UVW

Motor

Optional ground connection

+DC BR

Thermal

overload

protection

device

Output connections

Input connections

Mains

Supply

L1 L2

Optional

line reactor

Optional

EMC filter

Fuses

L1 L2 L3

+DC -DC

Internal

EMC filter

Supply ground

Heatsink fan supply connections

SPMAXX0X only

UVW

Motor

Optional ground connection

+DC

Thermal

overload

protection

device

Output connections

Input connections

Mains

Supply

L1 L2

Line reactor

(INLXXX)

Optional

EMC filter

Fuses

L1 L2

Supply

ground*Heatsink

fan supply

connections

SPMC/U

+DC -DC

Internal

EMC filter

+DC -DC

SPMD

SPMDXX0X only

Safety

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6.1 Power connections

6.1.1 AC and DC connections

Figure 6-1 Unidrive SPMA power connections

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Figure 6-2 Unidrive SPMD & SPMC/U (rectifier) power connections

* See section 6.1.2 Ground connections . ** See section 6-12 Location of the heatsink fan supply connections (SPMA & SPMD) on page 73 for more information.

Unidrive SPM User Guide 65 Issue Number: 3 www.controltechniques.com

* See section 6.1.2 Ground connections . ** See section 6-12 Location of the heatsink fan supply connections (SPMA & SPMD) on page 73 for more information.

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Supply ground

Motor ground

Supply ground

Motor ground

Supply ground

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For the dual rectifier, the power connections are repeated. See Figure 24 on page 9 for terminal identification.

A docking kit is available for electronically connecting the SPMD (inverter) to the SPMC/U (rectifier). See section 5.6.1 Installing the docking kit on page 39 for further details.

6.1.2 Ground connections

On a Unidrive SPMA, SPMD, SPMC/U the supply and motor ground connections are made using an M10 bolt at the top (supply) and bottom (motor) of the drive. See Figure 6-3 on page 66.

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

SPMA: 75mm SPMD: 120mm SPMC/U: 128mm

Figure 6-3 Unidrive SPMA ground connections

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Figure 6-4 Unidrive SPMD ground connections

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Figure 6-5 Unidrive SPMC/U ground connections

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Supply ground

Motor ground

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Figure 6-6 Unidrive SPMD and SPMC/U (rectifier) ground connections

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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 (removed) or additional independent motor ground fault protection must be provided. Refer to Table 6-1. For instructions on removal, refer to Figure 6-19 on page 80. For details of ground fault protection contact the supplier of the drive.

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

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

Table 6-1 Behaviour of the drive in the event of a ground (earth)

fault with an IT supply

Drive

size

SPMA SPMD

Internal filter only

May not trip – precautions required:

• Remove the EMC filter

• Use ground leakage relay

External filter (with

internal)

May not trip – precautions required:

• Do not use EMC filter

• Use ground leakage relay

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.

6.2 AC supply requirements

Voltage:

SPMX X2XX 200V to 240V ±10% SPMX X4XX 380V to 480V ±10%

SPMX X6XX 500V to 690V ±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 The maximum supply symmetrical fault current must be limited to 100kA

(also required for UL compliance).

6.2.1 Supply types

Drives rated for supply voltage up to 575V are suitable for use with any supply type, i.e. TN-S, TN-C-S, TT, IT, with grounding at any potential, i.e. neutral, centre or corner ("grounded-delta").

Grounded delta supplies >575V are not permitted.

6.2.2 Input line reactor specifications

A separate input line reactor of at least the value shown in Table 6-2 and Table 6-3 must be used with the rectifiers. Failure to provide sufficient reactance could damage or reduce the service life of the rectifier or inverter.

Figure 6-7 Input line reactor/output sharing choke dimensions

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NOTE

100

----------

-------

2π f I

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

×=

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Table 6-2 400V input line reactor ratings

Min

airflow

(m/s)

Quantity required

Part No.

Model

CurrentAInductance

μH

Overall

width (W)

Overall

depth (D)

Overall

height (H)

Weight

Max

ambient

temp (°C)

INL 401 245 63 240 190 225 32 50 1 1 4401-0181

INL 402 339 44 276 200 225 36 50 1 1 4401-0182 INL 401W* 245 63 255 235 200 27 40 3 1 4401-0208 INL 402W* 339 44 255 235 200 27 40 3 1 4401-0209

*May represent a more economic solution where operating temperature and cooling requirements are observed.

Table 6-3 400V dual input line reactor ratings

Min

airflow

(m/s)

Quantity

required

Part No.

Model

Current AInductance

μH

Overall

width (W)

Overall

depth (D)

Overall

height (H)

Weight

Max

ambient

temp (°C)

INL411 2 x 245 2 x 31.5 320 220 360 55 50 1 1 4401-0206 INL412 2 x 339 2 x 22 320 220 360 55 50 1 1 4401-0207

Table 6-4 690V input line reactor ratings

Min

airflow

(m/s)

Quantity

required

Part No.

Model

CurrentAInductance

μH

Overall

width (W)

Overall

depth (D)

Overall

height (H)

Weight

Max

ambient

temp (°C)

INL 601 145 178 240 190 225 33 50 1 1 4401-0183

INL 602 192 133 276 200 225 36 50 1 1 4401-0184

Table 6-5 690V dual input line reactor ratings

Model

Current

Inductance

μH

Overall

width (W)

Overall

depth (D)

Overall

height (H)

Weight

Max

ambient

temp (°C)

Min

airflow

(m/s)

Quantity required

Part No.

INL 611 2 x 145 2 x 89 320 220 360 40 50 1 1 4401-0190

INL 612 2 x 192 2 x 66.5 320 220 360 55 50 1 1 4401-0191

The INLX1X parallel line reactors have been designed to work in conjunction with the Unidrive SPMC/U, allowing one reactor to be used with the dual rectifier model or two separate rectifier units.

6.2.3 Supplies requiring additional line reactance

Additional line reactance reduces the risk of damage to the drive resulting from poor phase balance or severe disturbances on the supply network. It also reduces harmonic current emission. It can be implemented by adding external reactors with SPMA modules, and by adding additional series reactors or increased reactance values with rectifier modules.

Where additional line reactance is to be used, added reactance of approximately 2% is 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% additional reactance permits 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.

• Direct-on-line 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.

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

6.2.4 Additional input inductance calculation

To calculate the additional 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

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6.3 Output sharing choke specification

In order to achieve the best possible current sharing between paralleled Unidrive SPM modules, sharing chokes must be installed between the motor output connections and the drive’s motor connections.

Table 6-6 400V output sharing choke ratings

WeightkgMax ambient

temp

°C

Model

CurrentAInductanceμHWidth

(W)

Depth

(D)

Height

(H)

OTL401 221 40.1 240 220 210 20 50 1 SPMA/D 14X1 4401-0197 OTL402 267 34 242 220 205 20 50 1 SPMA/D 14X2 4401-0198 OTL403 313 28.5 242 220 205 25 50 1 SPMD 14X3 4401-0199 OTL404 378 23.9 242 220 205 25 50 1 SPMD 14X4 4401-0200

Table 6-7 600V output sharing choke ratings

WeightkgMax ambient

temp

°C

Model

CurrentAInductanceμHWidth

(W)

Depth

(D)

Height

(H)

OTL601 135 103.9 242 170 203 20 50 1 SPMA/D 16X1 4401-0201 OTL602 156 81.8 242 170 203 20 50 1 SPMA/D 16X2 4401-0202 OTL603 181 70.1 242 200 203 20 50 1 SPMD 16X3 4401-0203 OTL604 207 59.2 242 200 203 20 50 1 SPMD 16X4 4401-0204

6.3.1 Dual output sharing chokes

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

Min

airflow

m/s

Min

airflow

m/s

Required

SPM module

Required

SPM module

Part No.

Table 6-8 400V dual output sharing choke ratings

Model

CurrentAInductance

μH

Width

(W)

Depth

(D)

Height

(H)

WeightkgMax ambient

temp

°C

Min

airflow

m/s

Part No.

OTL411 390 42.8 300 150 160 8 50 1 4401-0188 OTL412 470 36.7 300 150 160 8 50 1 4401-0189 OTL413 551 31.1 300 150 160 8 50 1 4401-0192 OTL414 665 26.6 300 150 160 9 50 1 4401-0186

Table 6-9 600V dual output sharing choke ratings

Min

airflow

m/s

Part No.

Model

CurrentAInductance

μH

Width

(W)

Depth

(D)

Height

(H)

WeightkgMax ambient

temp

°C

OTL611 238 110.4 300 150 160 8 50 1 4401-0193 OTL612 274 88.4 300 150 160 8 50 1 4401-0194 OTL613 319 76.7 300 150 160 8 50 1 4401-0195 OTL614 365 65.7 300 150 160 8 50 1 4401-0196

6.3.2 Cooling requirements for higher output

frequencies

Single OTL output sharing chokes - OTLX0X

Up to output frequencies of 300Hz, 1m/s airflow provides adequate cooling.

Above 300Hz, the following equation must be used to calculate the required airflow:

0.75

S = (f

Where:

/72)

S is the airflow in metres per seconds

Dual OTL output sharing chokes - OTLX1X

The OTLX1X dual output sharing choke core does not see the change in drive output frequency as this choke is a current cancelling choke. Only the drives switching frequency has an effect on the core loss.

Therefore motor frequency is not an issue until higher frequencies cause high copper losses due to skin effect.

Therefore with the dual OTL chokes, only 1m/s airflow is required.

Maximum output frequency for OTL chokes

The maximum allowable output frequency for OTL output sharing chokes, singles or duals, should be limited to 1000Hz.

f is the drive output frequency in Hz

Example:

Output frequency is 450Hz

0.75

S = (450

/72)

= 1.4m/s

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Safety

L1 L2 L3

Supply

L1 L2 L3

SPMU

L1 L2 L3

Enable

24V

MCB1

DC+

DC-

Drive

DC+

DC-

Rectifier Status

Status

Motor

OPEN

CLOSED

OPEN

CLOSED

Under Voltage

Drive Healthy

Under

voltage

active

10.16

W1.45CV

××=

NOTE

1.56 Vll×

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

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6.4 Supplying the drive with DC / DC bus

paralleling

The drive may be supplied with DC instead of 3 phase AC. The connecting of the DC bus between several drives is typically used to:

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

2. Allow the use of one braking resistor to dissipate regenerative energy from several drives.

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

For further information, contact the supplier of the drive for the Application Note DC bus paralleling.

6.5 Resistor sizing for Unidrive SPMU

softstart

A separate soft-start must be provided for the DC bus of a Unidrive SPMD system when a Unidrive SPMC is not used. The start-up circuit limits the amount of current flowing into the DC bus of the drive when the supply is first switched on. The recommended configuration is shown in Figure 6-8.

Figure 6-8 Softstart circuit configuration

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K1: Main supply contactor to drive. K2: Soft-start contactor

2. Calculate the energy stored in the systems DC bus capacitance at the maximum supply voltage using:

R1: Soft-start resistor MCB1: Thermal / magnetic circuit breaker

K1 and K2 should be energized at the same time. MCB1 is normally closed Drive is not allowed to start until K1 has closed.

K1 is energized 3s after the drive OK parameter becomes active as shown in Figure 6-9

Figure 6-9 Switching sequence for K1 and K2

Where:

W: Maximum energy stored in the DC bus (Joules) C: Total DC bus capacitance (Farads) V

: Nominal line-to-line supply voltage (Volts)

20% over-rate has been applied to allow for component tolerances and a further 10% over-rate has been applied to allow for supply variations.

3. Calculate the minimum number of resistors required to meet this energy value (round up to the nearest one), (Table 6-12). Then calculate the series parallel arrangement of resistors to produce the total resistor value in the required range (Table 6-12 and Table 6-13).

4. Calculate the peak supply current and select the MCB. Ensure that the peak current is less than that shown in Table 6-10. If the current is too high, then choose a series / parallel arrangement of resistors that will give a higher resistance and therefore a lower peak current.

6.5.1 Procedure

Selection of the resistor and contactor is an iterative process requiring calculations based on the total DC bus capacitance, supply voltage and knowledge of the available parts.

1. Calculate the total DC bus capacitance of the system by simply

70 Unidrive SPM User Guide

adding the DC bus capacitances of each drive that is to be started by the soft-start circuit.

Where:

R: Total resistance of the soft-start resistor network. (Ohms) I

: Peak supply current (Amps)

The MCB must have a current rating no less than 13 x less than this

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peak current to avoid nuisance trips. See Figure 6-15. MCBs available from Control Techniques can be found in Table 6-13.

Page 71

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ch earg

5RC××=

It() Ipke

t–

RC×

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

⎝⎠

⎛⎞

×=

1.56 230×

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

14.95A pk==

ch earg

5 24 13200 106–××× 1.58s==

P R

---- the current needed to give 10 x power is=

P10

2960

------------- 11.1A==

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5. Calculate the start-up time.

Where:

: Approximate time to charge the DC bus.

charge

R: Total resistance of the soft-start resistor network. (Ohms)

Start-up time should not be less than 0.5s and generally should not be more than 4s although this upper limit can be chosen by the user. 1s charge time is recommended.

6. Calculate the supply current at 0.1s, 0.2s, 0.4s, 0.7s and 1s.

Where:

I(t): Peak current at time = t seconds.

Note that these calculation times are based on a 1s charge time. If the charge time not 1s, then the time steps can be calculated as follows.

Time interval

t1 = 0.1 x t t2 = 0.2 x t t3 = 0.4 x t t4 = 0.7 x t

t5 = t

charge

7. Compare the supply currents at time t1 to t5 with the circuit breaker worst-case trip characteristic. Make sure that the current is less than the trip curve for all the time intervals calculated.

8. Check that the MCB prevents the resistor from overheating. An example will best illustrate the process.

Example:

SPMD1204 on a 230Vac +10% line power supply.

Step 1

C = 13200µF

Step 2

-6

W = 1.45 x 13200 x 10

x 230

W = 1013J

Step 3

Select resistor CT part number 1270-2483 Number of resistors required = 1013 / 1700 = 0.6 One resistor is sufficient at 48Ω, but if a shorter start-up time is required,

then two resistors can be used in parallel giving 24Ω.

Step 4

Peak supply current is:

A 1.2A MCB is required.

Step 5

Calculate the start-up time:

A start-up time of 1.58s is acceptable.

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Step 6

Calculate the supply current throughout the start-up time.

Time

Supply Current

Apk

0.1 10.9

0.2 8.0

0.4 4.2

0.7 1.6

10.6

Step 7

Comparing the data from step 6 with the tripping characteristic of the selected MCB, Figure 6-11, shows that the supply current is less than the MCB trip curves for each time interval.

Step 8

To check that the MCB prevents the resistor from overheating assume a system fault which results in a continuous power of 10 x the nominal power being dissipated by the resistor.

Resistor selected earlier was 2 x 1270-2483 which is 24Ω 296W 10 x nominal power = 2960W

But the MCB current rating from step 4 was 1.2A

11.1A is 9 x the rated current From Figure 6-11 the MCB will trip in approximately 3s From the resistor manufacturer's data shown in Figure 6-10, 10 x rated

power can be withstood for 5s The MCB will protect the resistor. Design complete.

6.5.2 Design data

Capacitance

DC bus capacitance values and peak allowable supply current for Unidrive SPM drives are as follows.

Table 6-10 DC bus capacitance and peak supply current values

Model

capacitance

µF

SPMA14X1 4400 SPMA14X2 5500

Total DC bus

SPMA16X1 SPMA16X2

2200 52

SPMD12X1 8800 SPMD12X2 11000 SPMD12X3 SPMD12X4

13200

SPMD14X1 4400 52 SPMD14X2 5500

SPMD14X4 SPMD16X1 SPMD16X2 SPMD16X3 SPMD16X4

6600

2200

2933

Softstart resistor

The following resistors can be configured in series and parallel arrangements to meet the requirements.

Maximum allowable peak supply current

70SPMD14X3

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PR×

10.9

-----------

12 5

Duration of Load (seconds)

% Multiples of rated Power

100

20 25 50 100

0.01

0.02

0.04

0.06

0.1

0.2

0.4

0.6

120

1.5 2 3 41 56

810152030

Tripping time

Seconds Minutes

Multiple of rated current

Thermal Trip

Area

Hot

Cold

Magnetic Trip

Area

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Table 6-11 Available resistors

Resistor

value

Power

rating

Energy

rating

CT part

number

P x R

product

150 53 170 1270-3157 7950

48 148 1,700 1270-2483 7104

If it is difficult to find a suitable resistor then a resistor with a higher P x R product may have to be used.

The P x R product of the resistor should be larger than:

Table 6-12 Allowable Softstart resistor range

CT part number

SPMA14X1 SPMD14X1

Min. Resistance Ω Max. Resistance

30 300

SPMD12X1 SPMA14X2

24 240

SPMD14X2 SPMA16X1

SPMA16X2 SPMD16X1

105 1051

SPMD16X2 SPMD12X2

SPMD14X3

20 200

SPMD14X4 SPMD16X3

SPMD16X4 SPMD12X3

SPMD12X4

79 789

17 168

For multiple modules, divide the resistance by the number of modules. For example the minimum resistance for 3 x SPMD1404 is 6.7Ω.

Figure 6-10 Example of resistor overload characteristic

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Table 6-13 MCBs available from Control Techniques

CT part

number

Rated current Rated voltage No of poles

4133-0117 0.3 480 1 4133-0217 1 480 1 4133-0277 2 480 1

Figure 6-11 Example of tripping characteristic

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Circuit Breaker

Protection for the softstart circuit must be provided. The recommended protection is to use a miniature circuit breaker (MCB) having a thermal magnetic trip. The thermal part of the tripping mechanism protects against a high impedance short circuit and the magnetic part of the trip protects the resistor against a direct short circuit.

Many different MCBs are possible, e.g.:

• GB2CB range from Telemecanique

• S 281-K range from ABB

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55 54 53 52 51 50

65 64 63 62 61 60

To the heatsink fan

0V 24V low voltage DC mode enable

24V heatsink fan supply

Upper terminal connector

Lower terminal connector

Rectifier status 1 input

Rectifier status 0 input

NOTE

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6.6 Heatsink fan supply

The heatsink fan on Unidrive SPMA and SPMD requires an external 24Vdc supply. The connections for the heatsink fan supply must be made to the upper terminal connector near to the W phase output on the drive. Figure 6-12 shows the position of the heatsink fan supply connections.

Figure 6-12 Location of the heatsink fan supply connections

(SPMA & SPMD)

Figure 6-13 Heatsink fan supply connections (SPMA & SPMD)

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SPMD16X1 and 16X2 4A fast blow (I SPMD16X3 and 16X4 6.3A fast blow (I

The recommended wire gauge for the fan supply and low voltage mode enable is 1mm

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t <100A2s)

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For further information on the operation of the heatsink fan, refer to section 5.9 Heatsink fan operation on page 54.

6.7 Control 24Vdc supply

The 24Vdc input on the Unidrive SPMA and SPMD has three main functions.

• It can be used to supplement the drive’s own internal 24V when multiple SM-Universal Encoder Plus, or SM-I/O Plus modules are being used and the current drawn by these modules is greater than the drive can supply. (If too much current is drawn from the drive, the drive will initiate a 'PS.24V' trip)

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

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

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

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

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

The heatsink fan supply requirements are as follows:

Nominal voltage: 24Vdc Minimum voltage: 23.5Vdc Maximum voltage: 27Vdc Current drawn:

SPMA (all) 3.3A SPMD12X1 to 12X4 3.3A SPMD14X1 and 14X2 3.3A SPMD14X3 and 14X4 4.5A SPMD16X1 and 16X2 3.3A

SPMD16X3 and 16X4 4.5A Recommended power supply: 24V, 5A Recommended fuse:

SPMA (all) 4A fast blow (I

SPMD12X1 to 12X4 4A fast blow (I

SPMD14X1 and 14X2 4A fast blow (I

SPMD14X3 and 14X4 6.3A fast blow (I

t <20A2s)

t <100A2s)

6.8 Low voltage DC power supply

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

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

Unidrive SPMD (200V drives)

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

Unidrive SPMA and SPMD (400V and 690V drives)

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

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

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

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

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6.9 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.

Table 6-15 Unidrive SPMA input current, fuse and cable size ratings

Model

SPMA14X1 SPMA14X2 SPMA16X1 SPMA16X2

Fuse option 1

Typical

input

current

Maximum

input

current

IEC class gR

IEC class

Ferraz HSJ

North

America:

Ferraz HSJ

AA A A A A

224 247 128 144

241 315 300 250 315 2 x 70 2 x 2/0 2 x 70 2 x 2/0 B2 266 315 300 315 350 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B2 138 200 200 200 200 2 x 50 2 x 1 2 x 50 2 x 1 B2 156 200 200 200 200 2 x 50 2 x 1 2 x 50 2 x 1 B2

HRC AND

IEC class gG

UL class J

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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 6-14.

Table 6-14 Supply fault current used to calculate maximum input

currents

Model Symmetrical fault level (kA)

SPMA

100SPMD

SPMC/U

Fuse protection must be provided at the power input.

Fuse option 2

Semi-conductor

HRC

Semi-

conductor

IEC class aR

AC input Motor output

Typical cable size

AWG

Cable

installation

AWG

method

Table 6-16 Unidrive SPMD input current, fuse and cable size ratings

Typical cable size

AWG

Cable

AWG

installation

methodAA V A

Model

Typical DC

input

current

Maximum DC input current

Maximum DC

input voltage for

cable rating

DC fuse

IEC class aR

DC input Motor output

SPMD12X1 202 343 400 400 2 x 70 2 x 2/0 2 x 70 2 x 2/0 B2 SPMD12X2 261 400 400 560 2 x 95 2 x 4/0 2 x 120 2 x 4/0 B2 SPMD12X3 338 457 400 560 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B2 SPMD12X4 372 552 400 560 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B1 or C SPMD14X1 222 343 800 400 2 x 70 2 x 2/0 2 x 70 2 x 2/0 B2 SPMD14X2 268 400 800 560 2 x 95 2 x 4/0 2 x 120 2 x 4/0 B2 SPMD14X3 314 457 800 560 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B2 SPMD14X4 379 552 800 560 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B1 or C SPMD16X1 135 191 1150 250 2 x 95 2 x 4/0 2 x 50 2 x 1 B2 SPMD16X2 157 240 1150 315 2 x 120 2 x 4/0 2 x 50 2 x 1 B2 SPMD16X3 184 275 1150 350 2 x 120 2 x 4/0 2 x 50 2 x 1 B2 SPMD16X4 209 323 1150 400 2 x 120 2 x 4/0 2 x 50 2 x 1 B2

Fuse ratings are for a DC supply or paralleled DC bus arrangements. When supplied by a single SPMC or SPMU of the correct rating, the AC input fuses provide protection for the drive and no DC fuse is required.

Table 6-17 Unidrive SPMC/U 400V input current, fuse and cable size rating

Semiconductor fuse in

series with HRC fuse

HRC IEC

Class gG UL

class J

Semi-

conductor

IEC class aR

AC input DC output cable

Model

Maximum

input

current

Typical

output

current

AA A A

SPMC/U1402 344 379 450 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B1 or C

Typical cable size

AWG

Cable

installation

AWG

method

SPMC/U2402 2 x 312 2 x 345 450 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0 B1 or C

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Table 6-18 Unidrive SPMC/U 690V input current, fuse and cable size ratings

Semiconductor fuse in

series with HRC fuse

HRC IEC

Class gG UL

class J

conductor

IEC class aR

Semi-

Model

Maximum

input

current

Typ ica l

output

current

AA A A

SPMC/U1601 195 209 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0 B2

SPMC/U2602 2 x 173 2 x 185 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0 B2

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Typical cable size

AC input DC output cable

AWG

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Cable

method

The cable sizes noted in Table 6-15, Table 6-16, Table 6-17 and Table 618 are typical cable sizes based on UL508C and IEC60364-5-52:2001.

Maximum cable sizes are 2 x 240mm

or 2 x 400kcmil per pole. The user will have to decide what size of cable to use in any given application based on the local wiring regulations. Use of high temperature cables that are thinner than those stated in the typical cable chart maybe possible, contact the supplier of the drive for advice.

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

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

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

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

Owing to the high level of current on the input of SPMD1404 and the output of SPMC1402 and SPMU1402, the cable installation method must be B1 or C rather than B2 if the ambient is 40°C. Installation method B1 is separate cables in conduit and installation method C is multicore cable in free air.

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

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

UL listing is dependent on the use of the correct type of UL-listed fuse. See Chapter 16 UL Listing Information on page 294 for sizing information.

Fuses

The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Table 6-15, Table 6-16, Table 6-17 and Table 6-18 show recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

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

Fuse types

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

IEC Fuse types

• IEC class gG - Full range breaking capability in general application. Slow acting.

• IEC class gR - Dual rated: semiconductor protection (ultra-fast acting) and cable protection.

• IEC class aR - Semiconductor Protection, fast acting. Provides no protection from slow, small overloads, so cable must be protected by using a gG fuse or circuit breaker.

• HRC- High Rupturing Capacity – Denotes the ability of the fuse link to interrupt extremely high fault currents.

North American Fuse Types

• UL class J - Full range breaking capability in general application. Slow acting. Up to 600V only.

• Ferraz HSJ -High speed class J fuses. Dual rated: semiconductor protection (ultra-fast acting) and cable protection. Up to 600V only and only from Ferraz.

Ground connections

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

6.9.1 Main AC supply contactor

The recommended AC supply contactor type is AC1.

6.10 Output circuit and motor protection

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

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

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

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

6.10.1 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 6-19 and Table 6-20.

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

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Normal capacitance

Shield or armor separated from the cores

High capacitance

Shield or armor close to the cores

Motor

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Chain

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Table 6-19 Maximum motor cable lengths (Unidrive SPMA)

Maximum permissible motor cable length for

Model

each of the following frequencies

3kHz 4kHz 6kHz

SPMA14X1 SPMA14X2 SPMA16X1

250m (820ft) 185m (607ft) 125m (410ft)

SPMA16X2

Table 6-20 Maximum motor cable lengths (Unidrive SPMD)

Maximum permissible motor cable length for

Model

each of the following frequencies

3kHz 4kHz 6kHz

SPMD12X1 SPMD12X2 SPMD12X3 SPMD12X4 SPMD14X1 SPMD14X2 SPMD14X3

250m (820ft) 185m (607ft) 125m (410ft)

SPMD14X4 SPMD16X1 SPMD16X2 SPMD16X3 SPMD16X4

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

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

High-capacitance cables

The maximum cable length is reduced from that shown in Table 6-19 and Table 6-20 if high capacitance motor cables are used.

Most cables have an insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended. Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted in the tables. (Figure 6-14 shows how to identify the two types.)

Figure 6-14 Cable construction influencing the capacitance

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

• AC supply voltage exceeds 500V

• DC supply voltage exceeds 670V

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

• Multiple motors connected to a single drive

For multiple motors, the precautions given in section 6.10.3 Multiple motors should be followed.

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

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

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

6.10.3 Multiple motors

Open-loop only

If the drive is to control more than one motor, one of the fixed V/F modes should be selected (Pr 5.14 = Fd or SrE). Make the motor connections as shown in Figure 6-15 and Figure 6-16. The maximum cable lengths in Table 6-19 and Table 6-20 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 A connection, a sinusoidal filter or an output inductor must be connected as shown in Figure 6-16, even when the cable lengths are less than the maximum permissible. For details of inductor sizes refer to the supplier of the drive.

Figure 6-15 Preferred chain connection for multiple motors

The cable used for Table 6-19 and Table 6-20 is shielded and contains four cores. Typical capacitance for this type of cable is 130pF/m (i.e. from one core to all others and the shield connected together).

6.10.2 Motor winding voltage

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

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

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Figure 6-16 Alternative connection for multiple motors

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The Drive Enable terminal (T31) when opened provides a SAFE TORQUE OFF (SECURE DISABLE) function. This can in many cases replace output contactors.

For further information see section 6.19 SAFE TORQUE OFF (SECURE DISABLE) on page 99.

6.11 Braking

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

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

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

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

Table 6-21 shows the DC voltage level at which the drive turns on the braking transistor.

Table 6-21 Braking transistor turn on voltage

Drive voltage rating DC bus voltage level

200V 390V 400V 780V 690V 1120V

6.10.4 A / Δ motor operation

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

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

400V drive 400V rated voltage

A typical 3 phase motor would be connected in

for 400V operation or

Δ for 200V operation, however, variations on this are common e.g.

690V Δ 400V

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

6.10.5 Output contactor

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

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

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

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

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

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear

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

High temperatures

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

6.11.1 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 6-17 on page 78.

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 6.13.5 Compliance with generic emission standards on page 84 for further details.

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

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Optional RFI filter

Stop

Start / Reset

Thermal protection device

Braking resistor

Drive

Main contactor power supply

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Minimum resistances and power ratings

Table 6-22 Minimum resistance values and peak power rating for

the braking resistor at 40°C (104°F)

Model

Minimum

resistance*

Instantaneous power rating**

Average power

for 60s

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 6-17 shows a typical circuit arrangement.

Figure 6-17 Typical protection circuit for a braking resistor

SPMA1401 5 122 122 SPMA1402 5 122 122 SPMA1601 10 125 113 SPMA1602 10 125 125 SPMD1201 2.5 61 61 SPMD1202 2.5 61 61 SPMD1203 1.9 80 80 SPMD1204 1.9 80 80 SPMD1401 5 122 122 SPMD1402 5 122 122 SPMD1403 3.8 160 160 SPMD1404 3.8 160 160 SPMD1601 10 125 113 SPMD1602 10 125 125 SPMD1603 6.2 202 165 SPMD1604 6.2 202 198

* Resistor tolerance: ±10% ** Continuous rating if drive is part of a common DC bus system. In

parallel systems without the DC bus connected, the resistors must be matched to within ±5%.

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

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

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

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

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

See Figure 6-1 and Figure 6-2 on page 65 for the location of the +DC and braking resistor connections.

6.11.2 Braking resistor software overload protection

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

• Resistor short-time overload time (Pr 10.30)

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

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

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

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

See the Unidrive SP Advanced User Guide for more information on Pr 10.30, Pr 10.31, Pr 10.37 and Pr 10.39.

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

Braking Resistor Connections

This section details the rules that govern the connection of braking resistors to a parallel application. The braking resistor should be

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connected across the brake and +DC terminals.

1. The brake terminals must not be connected together. Each module must have its own resistor if required.

2. The resistor connected to each module must not have a value less than the recommended minimum value for that module size.

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3. The total power rating must not be less than the maximum expected regenerative power.

4. If the DC buses are separate and the modules are all the same rating, the brake resistors must match to better than 5% at all power flows. (If the temperature coefficient and/or temperature rise of the resistor is significant then the cooling must also match to ensure the resistors are at similar temperatures and hence similar resistance values.)

5. If the DC buses are common the brake resistors do not need to match. However to use the drive's brake resistor protection algorithm it must be set up to protect the most vulnerable resistor.

6.12 Ground leakage

The ground leakage current depends upon whether the internal EMC filter is installed. The drive is supplied with the filter installed. Instructions for removing the internal filter are given in Figure 6-19 on page 80.

With internal filter installed:

56mA AC at 400V 50Hz (proportional to supply voltage and frequency) 30µA DC (10MΩ)

With internal filter removed:

<1mA

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

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

6.12.1 Use of residual current device (RCD)

There are three common types of ELCB / RCD:

1. AC - detects AC fault currents

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

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

• Type AC should never be used with drives.

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

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The recommendations of section 6.13.3 will usually be sufficient to avoid causing disturbance to adjacent equipment of industrial quality. If particularly sensitive equipment is to be used nearby, or in a nonindustrial environment, then the recommendations of section 6.13.4 or section 6.13.5 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 14 Technical Data on page 263 ...the correct external EMC filter must be used and all of the guidelines in

section 6.13.3 General requirements for EMC and section

6.13.5 Compliance with generic emission standards must be followed.

High ground leakage current

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

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

6.13.1 Grounding hardware

The master/slave interface is supplied with a grounding clamp and a grounding bracket to facilitate EMC compliance. They provide a convenient method for direct grounding of cable shields without the use of "pig-tails". Cable shields can be bared and clamped to the grounding

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

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

(for cables with a maximum outer diameter of 14mm). See Figure 6-18 for details on installing the grounding bracket.

Figure 6-18 Installation of grounding bracket (master/slave)

(not supplied) or cable ties. Note

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

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

6.13 EMC (Electromagnetic compatibility)

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

Section 6.13.3, General requirements for all applications, to ensure reliable operation of the drive and minimise the risk of disturbing nearby equipment. The immunity standards specified in section 11 will be met, but no specific emission standards. Note also the special requirements given in Surge immunity of control circuits - long cables and connections outside a building on page 86 for increased surge immunity of control circuits where control wiring is extended.

Section 6.13.4, Requirements for meeting the EMC standard for power drive systems, IEC61800-3 (EN61800-3).

Section 6.13.5, Requirements for meeting the generic emission standards for the industrial environment, IEC61000-6-4, EN61000-6-4,

EN50081-2.

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

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

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6.13.2 Internal EMC filter

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

When the drive is used with ungrounded (IT) supplies the internal EMC filter must be removed unless additional motor ground fault protection is installed. For instructions on removal, refer to Figure 6-19 Removal of internal EMC filter on page 80. For details of ground fault protection contact the supplier of the drive.

If the drive is used 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 EN61800-3 to be met for the second environment - see section 6.13.4 Compliance with EN 61800-3 (standard for Power Drive

Systems) on page 83 and section 14.1.26 Electromagnetic compatibility (EMC) on page 272. For longer motor cables the filter continues to

provide a useful reduction in emission level, and when used with any length of shielded motor cable up to the limit for the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the ground leakage current of 56mA is unacceptable or the above conditions are true. See Figure 6-19 for details of removing and installing the internal EMC filter.

Figure 6-19 Removal of internal EMC filter

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

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Safety

Metal backplate

Optional

ground

connection

External

controller

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

system controller only to

avoid injecting noise

currents into the 0V circuit

Grounding bar

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

Use four core cable to

connect the motor to the drive.

The ground conductor in the motor cable must be connected

directly to the earth terminal of

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

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

3 phase AC supply

Optional EMC filter

Metal backplate

safety bonded to

power ground busbar

Information

6.13.3 General requirements for EMC

Ground (earth) connections

The grounding arrangements should be in accordance with Figure 6-20, which shows a single drive on a back-plate with or without an additional enclosure.

Figure 6-20 shows how to manage EMC when using an unshielded motor cable. However a shielded cable is preferable, in which case it should be installed as shown in section 6.13.5 Compliance with generic emission standards on page 84.

Figure 6-20 General EMC enclosure layout showing ground connections

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Page 82

Safety

Optional braking

resistor and overload

Do not place sensitive (unscreened) signal circuits in a zone extending 300mm (12”) all around the Drive, motor cable, input cable from RFI filter and unscreened braking resistor cable (if used)

300mm

(12in)

NOTE

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Cable layout

Figure 6-21 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment.

Figure 6-21 Drive cable clearances

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

Feedback device cable shielding

Shielding considerations are important for PWM drive installations due to the high voltages and currents present in the output (motor) circuit with a very wide frequency spectrum, typically from 0 to 20 MHz.

The following guidance is divided into two parts:

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1. Ensuring correct transfer of data without disturbance from electrical noise originating either within the drive or from outside.

2. Additional measures to prevent unwanted emission of radio frequency noise. These are optional and only required where the installation is subject to specific requirements for radio frequency emission control.

To ensure correct transfer of data, observe the following:

Resolver connections:

• Use a cable with an overall shield and twisted pairs for the resolver signals

• Connect the cable shield to the drive 0V connection by the shortest possible link ("pigtail")

• It is generally preferable not to connect the cable shield to the resolver. However in cases where there is an exceptional level of common-mode noise voltage present on the resolver body, it may be helpful to connect the shield there. If this is done then it becomes essential to ensure the absolute minimum length of "pigtails" at both shield connections, and possibly to clamp the cable shield directly to the resolver body and to the drive grounding bracket.

• The cable should preferably not be interrupted. If interruptions are unavoidable, ensure the absolute minimum length of "pigtail" in the shield connections at each interruption.

Encoder connections:

• Use a cable with the correct impedance

• Use a cable with individually shielded twisted pairs

• Connect the cable shields to 0V at both the drive and the encoder, using the shortest possible links ("pigtails")

• The cable should preferably not be interrupted. If interruptions are unavoidable, ensure the absolute minimum length of "pigtail" in the shield connections at each interruption. Preferably, use a connection method which provides substantial metallic clamps for the cable shield terminations.

The above applies where the encoder body is isolated from the motor and where the encoder circuit is isolated from the encoder body. Where there is no isolation between the encoder circuits and the motor body, and in case of doubt, the following additional requirement must be observed. This gives the best possible noise immunity.

• The shields must be directly clamped to the encoder body (no pigtail) and to the drive grounding bracket. This may be achieved by clamping of the individual shields or by providing an additional overall shield which is clamped.

The recommendations of the encoder manufacturer must also be adhered to for the encoder connections.

In order to guarantee maximum noise immunity for any application double shielded cable as shown should be used.

In some cases single shielding of each pair of differential signals cables, or a single overall shield with individual shield on the thermistor connections is sufficient. In these cases all the shields should be connected to ground and 0V at both ends.

If the 0V is required to be left floating a cable with individual shields and an overall shield must be used.

Figure 6-22 and Figure 6-23 illustrate the preferred construction of cable and the method of clamping. The outer sheath of the cable should be stripped back enough to allow the clamp to be installed. The shield must not be broken or opened at this point. The clamps should be installed close to the drive or feedback device, with the ground connections made to a ground plate or similar metallic ground surface.

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Safety

Twisted

pair

cable

Twisted pair shield

Cable

Cable overall shield

Cable

Cable shield

Twisted

pair

shield

Cable shield

Twisted

pair

shield

Connection

at motor

Connection

at drive

Ground clamp on shield

Shield

connection

to 0V

Shield

connection

to 0V

CAUTION

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Figure 6-22 Feedback cable, twisted pair

Figure 6-23 Feedback cable connections

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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 Unidrive SPs with a rated input current of less than 100A.

The drive contains an in-built filter for basic emission control. In some cases feeding the motor cables (U, V and W) once through a ferrite ring can maintain compliance for longer cable lengths. The requirements of operating in the second environment are met, depending on the motor cable length for 3kHz switching frequency as stated in Table 6-23.

The table summarizes the performance of in-built filters when used with SPMA drives and single pairs of SPMD drives and SPMC/U rectifiers, assembled in the standard recommended configuration.

Table 6-23 Second environment emission compliance

Drive size Filter Voltage Motor cable length 0 - 100 (m)

SPMA In-built Any Unrestricted

SPMD In-built Any Unrestricted

Key:

Unrestricted: EN 61800-3 second environment, unrestricted

distribution

For longer motor cables, an external filter is required. Where a filter is required, follow the guidelines in section 6.13.5 Compliance with generic emission standards .

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

6.13.3 General requirements for EMC on page 81.

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 6.13.5 Compliance with generic emission standards be adhered to.

Refer to section 14.1.26 Electromagnetic compatibility (EMC) on page 272 for further information on compliance with EMC standards and definitions of environments.

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

To ensure suppression of radio frequency emission, observe the following:

• Use a cable with an overall shield

• Clamp the overall shield to grounded metallic surfaces at both the encoder and the drive, as illustrated in Figure 6-23

6.13.4 Compliance with EN 61800-3 (standard for

Power Drive Systems)

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

Operation in the first environment

Observe the guidelines given in section 6.13.5 Compliance with generic emission standards on page 84. 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.

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Page 84

Safety

≥

100mm (4in)

≥

100mm

(4in)

≥

100mm (4in)

≥

300mm

(12in)

Sensitive

signal cable

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6.13.5 Compliance with generic emission standards

Use the recommended filter and shielded motor cable. Observe the layout rules given in Figure 6-24. Ensure the AC supply and ground cables are at least 100mm from the power module and motor cable.

Figure 6-24 Supply and ground cable clearance

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Avoid placing sensitive signal circuits in a zone 300mm (12in) all around the power module.

Figure 6-25 Sensitive signal circuit clearance

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Safety

Motor cable screen (unbroken) physically fixed to the backplate.

Ensure direct metal contact at drive and filter (not shown) mounting points (any paint must be removed).

+DC BR

Optional external

braking resistor

Enclosure

+DC BR

Optional external

braking resistor

Enclosure

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Ensure good EMC grounding.

Figure 6-26 Grounding the drive, motor cable shield and filter

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Unshielded wiring to the optional braking resistor(s) may be used, provided the wiring does not run external to the enclosure. Ensure a minimum spacing of 300mm (12in) from signal wiring and the AC supply wiring to the external EMC filter. Otherwise this wiring must be shielded.

Figure 6-28 Shielding requirements of optional external braking

resistor

Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50mm

(2in) long. A full 360

termination of the shield to the terminal housing of

the motor is beneficial. It is unimportant for EMC purposes whether the motor cable contains an

internal (safety) ground core, or there is a separate external ground conductor, or grounding is through the shield alone. An internal ground core will carry a high noise current and therefore it must be terminated as close as possible to the shield termination.

Figure 6-27 Grounding the motor cable shield

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Page 86

Safety

Ground screw

Screen wire

From

the

Drive

To the

motor

Back-plate

Enclosure

Isolator

Coupling bar

From the Drive

To the motor

(If

required)

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If the control wiring is to leave the enclosure, it must be shielded and the shield(s) clamped to the drive using the grounding bracket as shown in Figure 6-29. Remove the outer insulating cover of the cable to ensure the shield(s) make contact with the bracket, but keep the shield(s) intact until as close as possible to the terminals

Alternatively, wiring may be passed through a ferrite ring, part no. 3225-

1004.

Figure 6-29 Grounding of signal cable shields using the

grounding bracket

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Terminal block in the enclosure

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

Figure 6-31 Connecting the motor cable to a terminal block in the

enclosure

Figure 6-30 Grounding of SPMC/U signal cables

6.13.6 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.

Using a motor isolator/disconnect-switch

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

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

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

Figure 6-32 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 EN61000-6-2 (1kV surge) provided the 0V connection is not grounded.

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

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

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Safety

Signal from plant Signal to drive

0V 0V

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

Signal from plant Signal to drive

0V 0V

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

NOTE

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1. Galvanic isolation, i.e. do not connect the control 0V terminal to

ground. Avoid loops in the control wiring, i.e. ensure every control wire is accompanied by its return (0V) wire.

2. Shielded cable with additional power ground bonding. The cable

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

cross-sectional area of at least 10mm

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

3. Additional over-voltage suppression - for the analog and digital inputs and outputs, a zener diode network or a commercially available surge suppressor may be connected in parallel with the input circuit as shown in Figure 6-33 and Figure 6-34.

If a digital port experiences a severe surge its protective trip may operate (O.Ld1 trip code 26). For continued operation after such an event, the trip can be reset automatically by setting Pr 10.34 to 5.

Figure 6-33 Surge suppression for digital and unipolar inputs and

outputs

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6.14 SPMC/U control connections

The rectifier must be supplied from an external 24V 3A supply to feed the fans and control circuits. When supplied with 24V and the three phase line power input are in tolerance, the rectifier is able to provide the user with x1 rectifier OK contact, x2 status outputs to the SPMD inverter (indicating the status of the rectifier), and x2 status inputs for applications using more than one rectifier in parallel (see Figure 6-36)

Figure 6-35 Location of SPMC (rectifier) control terminals

Figure 6-34 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.

The external 24V supply must be connected to enable the Unidrive SPMC/U.

When the Unidrive SPMC/U is connected to a Unidrive SPMD, the status output connections must be connected as shown in Figure 6-36.

Unidrive SPMC/U external 24V supply requirements

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

Recommended fuse:

4A fast blow (I2t <20A2s)

If the Unidrive SPM power supply (CT part number 8510-0000) is used to supply the Unidrive SPMA/D or SPMC/U, a fuse on the 24V supply to the SPMC/U is not required.

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Unidrive SPM power supply

CT part number: 8510-0000 Current rating: 10A Input voltage: 85 to 123 / 176 to 264Vac auto switching

Cable size: 0.5mm Fuse: 5A slow-blow from supply

(20AWG)

Page 88

Safety

Fan control 0V common

Single Module Rectifier

SPMC/U

Status input 0 0V common

Status input 1 0V common

External 24V supply 0V common

Status output 0 0V common

Status output 1 0V common

Inverter (master)

SPMD

Status 0 input

0V common

Status 1 input

0V common

Relay contacts

Rectifier OK

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6.14.1 SPMC Hardware configuration - Single module

When a Unidrive SPMC is used to supply the DC Bus of SPMD, the status output lines can be taken from the SPMC and feed directly into the status inputs of the SPMD. The inverter will monitor the status lines and on detection of a trip disable the system.

Figure 6-36 Single module control terminals and descriptions

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Fan control

0V common

SPMC/U 2

Status input 0 0V common

Status input 1 0V common

External 24V

supply 0V common

Status output 0

0V common

Status output 1

0V common

606162

Inverter (master)

SPMD

Status 0 input

0V common

Status 1 input

0V common

Relay contacts

Rectifier OK

Fan control 0V common

SPMC/U 1

Status input 0 0V common

Status input 1 0V common

External 24V supply 0V common

Status output 0 0V common

Status output 1 0V common

Relay contacts

Rectifier OK

NOTE

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6.14.2 SPMC/U Hardware configuration - Multiple Rectifier modules

Figure 6-37 Parallel rectifier control terminals and descriptions

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6.14.3 Unidrive SPMC/U control connections

Status input connections

70 0V common

71 Status input 1

72 0V common

73 Status input 0

Function

Logic 0 voltage level <8.4V Logic 1 voltage level >8.4V Open circuit voltage level -4.8V source resistance 8.7k Input resistance

Fan control connections

74 0V common

75 Fan control

Function

Voltage range 0V to 24V supply voltage +2V Input threshold 10V Input resistance

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Status output connections

80 0V common

To allow status monitoring for applications using more than one rectifier

15k

The internal fan in the rectifier is controlled by a temperature control loop. The fan can be forced to run at full speed by connecting this terminal to +24V

6.8k

81 Status output 1

82 0V common

83 Status output 0

Provides status monitoring from

Function

the rectifier to the connecting drive / monitoring equipment to trip the rectifier unit

Logic 0 voltage level 0V Logic 1 voltage level 24V supply voltage Source resistance 1k1

When a system contains paralleled Unidrive SPMC/Us, the rectifier’s status outputs must be daisy chained to the status inputs of the next. Providing the system is fused correctly, the method used to monitor the rectifier status must have the ability to disable the system within 500ms. A PLC can be used to monitor the status output of the rectifier. PLC input impedance must be no greater than 10kΩ. Status signals are not latched.

84 0V common

Function

Common connection for all external devices

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Safety

Status 1 (S1) Status 0 (S0)

55 54 53 52 51 50

65 64 63 62 61 60

Low voltage DC mode enable

Not connected

24V heatsink fan supply

Upper terminal connector

Lower terminal connector

To the heatsink fan

Pre-wired internally

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85 External +24V supply

The rectifier must be supplied with

Function

+24V to power the fans and control PCB

Nominal voltage +24Vdc Minimum continuous operating

voltage Maximum continuous operating

voltage Current consumption 3.0A Minimum start-up voltage +18V Recommended power supply 24V, 100W, 4.5A

Recommended fuse

Relay contacts

+23V

+28V

4A fast blow (I

t <20A2s)

Function Rectifier OK indicator

Contact rating

Contact minimum recommended rating

Relay state when rectifier is operating normally

Update period

0.4A AC 240V 4A DC 40V resistive load

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

12Vdc 100mA

Closed

Relay is not latched, relay could change state at a rate up to 30ms

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Table 6-25 Key to SPMU (rectifier) LEDs

Status Output

1: Left LED 0: Right LED

OFF OFF

Line power supply loss, or 24V supply to the rectifier has been lost

Meaning

• Internal fault

OFF ON

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

Any of the following:

ON OFF

• Rectifier heatsink over temperature

• Rectifier PCB over temperature

• Status input wire break

ON ON System OK

6.15 Low voltage DC mode enable, heatsink fan supply connections (SPMA/D) and status input connections (SPMD)

Unidrive SPMA and SPMD require a low voltage DC mode enable signal to terminal 50 and 51 of the lower terminal connector near the W phase output, to allow the drive to be used from a low voltage DC supply.

For more information regarding low voltage DC operation, see the Low Voltage DC Mode Application Note.

Figure 6-39 Location of the SPMA/D low voltage DC mode enable

connections

6.14.4 SPMC/U (rectifier) LEDs

The control circuitry of the Unidrive SPMC/U monitors the drive status and generates codes via the status output LEDs (S1 and S0).

Figure 6-38 Status LED location

The STATUS LEDs S0 and S1 mirror the status outputs and are encoded as follows:

Table 6-24 Key to SPMC (rectifier) LEDs

Status Output

1: Left LED

OFF OFF

0: Right LED

Line power supply, or 24V supply to the rectifier has been lost

OFF ON Phase loss

Any of the following:

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

ON OFF

• Rectifier heatsink over temperature

• Rectifier PCB over temperature

• Status input wire break

ON ON System OK

The SPMD drive will monitor the status lines and on detection of a fault disables the system via a PhP or (when used in conjunction with a SPMC) OHT4.P trip.

Meaning

Figure 6-40 SPMA low voltage DC mode enable connections

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55 54 53 52 51 50

65 64 63 62 61 60

Low voltage DC mode enable

Status inputs (from rectifier)

24V heatsink fan supply

Upper terminal connector

Lower terminal connector

To the heatsink fan

Pre-wired internally

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Figure 6-41 SPMD low voltage DC mode enable connections

6.15.1 Low voltage DC mode enable connections (SPMA/D)

50 0V

51 Low voltage DC mode enable

Function

To allow the drive to be used from a low voltage DC supply

Nominal voltage 24.0Vdc

Minimum continuous operating voltage

Maximum continuous operating voltage

19.2Vdc

30.0Vdc

Nominal current consumption 500mA

Recommended fuse

8A 600V AC fast acting class CC type fuse

6.15.2 Heatsink fan supply connections (SPMA/D)

Heatsink fan connections

No user connections

6.15.3 SPMA status input connections

No connection

No user connections

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6.15.4 SPMD status input connections

60 0V common

61 Status 1 input

62 0V common

63 Status 0 input

Function

To allow status monitoring from the SPMC/U rectifier module

Logic 0 voltage level <7.5V Logic 1 voltage level >7.5V I/P resistance 6.8kΩ Open circuit voltage level -15V (connected to -15V by 47kΩ)

6.15.5 External 24V heatsink fan supply (SPMA/D)

64 0V

65 24V heatsink fan supply

Function

Nominal voltage 24Vdc

Minimum continuous operating voltage

Maximum continuous operating voltage

Current consumption

Recommended power supply 24V, 5A

Recommended fuse

To provide the power supply to the heatsink mounted fan

23.5V

27V

SPMA (all): 3.3A SPMD12X1/12X4: 3.3A SPMD14X1/14X2: 3.3A SPMD14X3/14X4: 4.5A SPMD16X1/16X2: 3.3A SPMD16X3/16X4: 4.5A

SPMA (all): 4A fast blow (I

SPMD12X1/12X4: 4A fast blow (I

SPMD14X1/14X2: 4A fast blow (I

SPMD14X3/14X4:

6.3A fast blow (I SPMD16X1/16X2:

4A fast blow (I SPMD16X3/16X4:

6.3A fast blow (I

t >20A2s)

Diagnostics

t >100A2s)

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6.16 Serial communications connections

The drive has a serial communications port (serial port) as standard supporting 2 wire EIA485 communications. See Table 6-26 for the connection details for the RJ45 connector.

Figure 6-42 Location of the RJ45 serial comms connector

Table 6-26 Connection details for RJ45 connector

Pin Function

1 120Ω Termination resistor 2RX TX 3 Isolated 0V 4 +24V (100mA) 5 Isolated 0V 6 TX enable 7RX\ TX\ 8

Shell Isolated 0V

The communications port applies a 2 unit load to the communications network.

Minimum number of connections are 2, 3, 7 and shield. Shielded cable must be used at all times.

6.16.1 Isolation of the serial communications port

The serial communications port is double insulated and meets the requirements for SELV in EN50178.

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

Table 6-27 Isolated serial comms lead details

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

When using the CT EIA232 Comms cable the available baud rate is limited to 19.2k baud.

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

In order to meet the requirements for SELV in IEC60950 (IT equipment) it is necessary for the control computer to be grounded. Alternatively, when a lap-top or similar device is used which has no provision for grounding, an isolation device must be incorporated in the communications lead.

Part number Description

4500-0087 CT EIA232 Comms cable 4500-0096 CT USB Comms cable

6.16.2 Multi-drop network

The drive can be used on a 2 wire EIA485 multi-drop network using the drive's serial communications port when the following guidelines are adhered to.

Connections

The network should be a daisy chain arrangement and not a star, although short stubs to the drive are allowed.

The minimum connections are pins 2 (RX TX), 3 (isolated 0V), 7 (RX\ TX\) and the shield.

Pin 4 (+24V) on each drive can be connected together but there is no power sharing mechanism between drives and therefore the maximum power available is the same as a single drive. (If pin 4 is not linked to the other drives on the network and has an individual load then the maximum power can be taken from pin 4 of each drive.)

Termination resistors

If a drive is on the end of the network chain then pins 1 and 8 should be linked together. This will connect an internal 120Ω termination resistor between RXTX and RX\TX\. (If the end unit is not a drive or the user wishes to use their own termination resistor, a 120Ω termination resistor should be connected between RXTX and RX\TX\ at the end unit.)

If the host is connected to a single drive then termination resistors should not be used unless the baud rate is high.

CT Comms Cable

The CT Comms Cable can be used on a multi-drop network but should only be used occasionally for diagnostic and set up purposes. The network must also be made up entirely of Unidrive SPs.

If the CT Comms Cable is to be used, then pin 6 (TX enable) should be connected on all drives and pin 4 (+24V) should be linked to at least 1 drive to supply power to the converter in the cable.

Only one CT Comms Cable can be used on a network.

6.17 Control connections - master interface

6.17.1 General

Table 6-28 The Unidrive SPM control connections consist of:

Function Qty Control parameters available

Differential analog input 1

Single ended analog input

Analog output 2 Source, mode, scaling, 9,10 Digital input 3 Destination, invert, logic select 27,28,29

Digital input / output 3

Relay 1 Source, invert 41,42 Drive enable (SAFE

TORQUE OFF (SECURE DISABLE))

+10V User output 1 4 +24V User output 1 Source, invert 22

0V common 6

+24V External input 1 2

Destination, offset, offset trim, invert, scaling

Mode, offset, scaling, invert,

destination

Input / output mode select, destination / source, invert, logic select

131

Key:

Destination parameter:

Source parameter:

Mode parameter:

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

indicates the parameter being output by the terminal

analog - indicates the mode of operation of the terminal, i.e. voltage 0-10V, current 4-20mA etc.

digital - indicates the mode of operation of the terminal, i.e. positive / negative logic (the Drive Enable terminal is fixed in positive logic), open collector.

All analog terminal functions can be programmed in menu 7.

Ter mi nal

number

5,6

7,8

24,25,26

1, 3, 11, 21,

23, 30

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Polarized signal connectors

21 31

0V common External 24V supply

common

Analog frequency/speed reference 1

Connections for

single-ended

input

signal

Connections for

differential

input signal

0V common

Analog input 2

Analog input 1

common

256

32122

2324252627282930314142

At zero speed

Reset

Run forward

Run reverse

Analog input 1/

input 2 select

Jog forward select

SAFE TORQUE OFF

(SECURE DISABLE) /

Drive enable**

Status relay

Drive OK

Speed / frequency

0V common

Analog

frequency/speed

reference 2

4711910

Torque (active

current)

Analog input 3

Motor thermistor*

Information

Introduction

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

The setting of Pr 1.14 and Pr 6.04 can cause the function of digital inputs T25 to T29 to change. For more information, please refer to section

13.21.1 Reference modes on page 254 and section 13.21.7 Start / stop

logic modes on page 259.

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

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

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

Ensure the logic sense is correct for the control circuit to be used. Incorrect logic sense could cause the motor to be started unexpectedly. Positive logic is the default state for.

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Figure 6-43 Default terminal functions

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

The SAFE TORQUE OFF (SECURE DISABLE) / drive enable terminal is a positive logic input only. It is not affected by the setting of Pr 8.29 Positive logic select.

The common 0V from analog signals should, wherever possible, not be connected to the same 0V terminal as the common 0V from digital signals. Terminals 3 and 11 should be used for connecting the 0V common of analog signals and terminals 21, 23 and 30 for digital signals. This is to prevent small voltage drops in the terminal connections causing inaccuracies in the analog signals.

Unidrive SPM User Guide 93 Issue Number: 3 www.controltechniques.com

* With software V01.07.00 and later, Analog input 3 is configured as a motor thermistor input. With software V01.06.02 and earlier, Analog input 3 has no default function. Refer to Analog input 3 on page 94.

**The SAFE TORQUE OFF (SECURE DISABLE) / Drive enable terminal is a positive logic input only.

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6.17.2 SPMA and SPMD control terminal specification

1 0V common

Function

2 +24V external input

Function

Nominal voltage +24.0Vdc Minimum continuous operating

voltage Maximum continuous operating

voltage Minimum start-up voltage 21.6Vdc Recommended power supply 60W 24Vdc nominal Recommended fuse 3A, 50Vdc

3 0V common

Function

4 +10V user output

Function Supply for external analog devices

Voltage tolerance ±1% Nominal output current 10mA Protection Current limit and trip @ 30mA

Precision reference Analog input 1

5 Non-inverting input

6 Inverting input

Default function Frequency/speed reference

Type of input

Full scale voltage range ±9.8V ±1% Absolute maximum

voltage range Working common mode voltage

range Input resistance Resolution 16-bit plus sign (as speed reference) Monotonic Yes (including 0V) Dead band None (including 0V) Jumps None (including 0V) Maximum offset Maximum non linearity 0.3% of input Maximum gain asymmetry 0.5% Input filter bandwidth single pole ~1kHz

Sampling period

Common connection for all external devices

To supply the control circuit without providing a supply to the power stage

+19.2Vdc

+30.0Vdc

Common connection for all external devices

Bipolar differential analog (For single-ended use, connect terminal 6 to terminal 3)

±36V relative to 0V

±13V relative to 0V

Ω ±1%

100k

700

μV

250

μs with destinations as Pr 1.36, Pr 1.37

or Pr 3.22 in closed loop vector or servo mode. 4ms for open loop mode and all other destinations in closed loop vector or servo mode.

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7 Analog input 2

Default function Frequency/speed reference

Type of input

Mode controlled by... Pr 7.11

Operating in Voltage mode

Full scale voltage range ±9.8V ±3% Maximum offset ±30mV Absolute maximum voltage range ±36V relative to 0V Input resistance

Operating in current mode

Current ranges

Maximum offset Absolute maximum voltage

(reverse bias) Absolute maximum current +70mA Equivalent input resistance

Common to all modes

Resolution 10 bit + sign

Sample period

Bipolar single-ended analog voltage or unipolar current

>100k

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

250

μA

−36V max

Ω at 20mA

≤200

250

μs when configured as voltage input

with destinations as Pr 1.36, Pr 1.37, Pr 3.22 or Pr 4.08 in closed loop vector or servo mode. 4ms for open loop mode, all other destinations in closed loop vector or servo mode, or any destination when configured as a current input.

8 Analog input 3

Default function

Type of input

Mode controlled by... Pr 7.15

Operating in Voltage mode (default)

Voltage range ±9.8V ±3% Maximum offset ±30mV Absolute maximum voltage range ±36V relative to 0V Input resistance

Operating in current mode

Current ranges

Maximum offset Absolute maximum voltage

(reverse bias) Absolute maximum current +70mA Equivalent input resistance

Operating in thermistor input mode

Internal pull-up voltage <5V Trip threshold resistance

Reset resistance

Short-circuit detection resistance

Common to all modes

Resolution 10 bit + sign

Sample period

V01.07.00 and later: Motor thermistor input (PTC) V01.06.02 and earlier: Not configured

Bipolar single-ended analog voltage, unipolar current or motor thermistor input

>100k

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

μA

250

−36V max

Ω at 20mA

≤200

Ω ±10%

3.3k

Ω ±10%

1.8k

Ω ±40%

250

μs when configured as voltage input

T8 analog input 3 has a parallel connection to terminal 15 of the drive encoder connector.

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9 Analog output 1

10 Analog output 2

Terminal 9 default function

Terminal 10 default function Motor active current

Type of output

Mode controlled by... Pr 7.21 and Pr 7.24

Operating in Voltage mode (default)

Voltage range ±9.6V ±5% Maximum offset 100mV Maximum output current ±10mA Load resistance Protection 35mA max. Short circuit protection

Operating in current mode

Current ranges

Maximum offset Maximum open circuit voltage +15V Maximum load resistance

Common to all modes

Resolution 10-bit (plus sign in voltage mode)

Update period

OL> Motor FREQUENCY output signal CL> SPEED output signal

Bipolar single-ended analog voltage or unipolar single ended current

Ω min

0 to 20mA ±10% 4 to 20mA ±10%

μA

600

500

μs when configured as a high speed

250 output with sources as Pr 4.02, Pr 4.17 in all modes or Pr 3.02, Pr 5.03 in closed loop vector or servo mode. 4ms when configured as any other type of output or with all other sources.

24 Digital I/O 1

25 Digital I/O 2

26 Digital I/O 3

Terminal 24 default function AT ZERO SPEED output

Terminal 25 default function DRIVE RESET input

Terminal 26 default function RUN FORWARD input

Type

Input / output mode controlled by... Pr 8.31, Pr 8.32 and Pr 8.33

Operating as an input

Logic mode controlled by... Pr 8.29 Absolute maximum applied voltage

range Impedance Input thresholds 10.0V ±0.8V

Operating as an output

Open collector outputs selected Pr 8.30 Nominal maximum output current 200mA (total including terminal 22) Maximum output current 240mA (total including terminal 22)

Common to all modes

Voltage range 0V to +24V

Sample / Update period

Positive or negative logic digital inputs, positive or negative logic push-pull outputs or open collector outputs

±30V

μs when configured as an input with

250 destinations as Pr 6.35 or Pr 6.36. 600 when configured as an input with

destinations as Pr 6.29. 4ms in all other cases.

μs

11 0V common

Function

Common connection for all external devices

21 0V common

Function

Common connection for all external devices

22 +24V user output (selectable)

Terminal 22 default function +24V user output

Can be switched on or off to act as a fourth

Programmability

Nominal output current 200mA (including all digital I/O) Maximum output current 240mA (including all digital I/O) Protection Current limit and trip

digital output (positive logic only) by setting the source Pr 8.28 and source invert Pr 8.18

23 0V common

Function

Common connection for all external devices

27 Digital Input 4

28 Digital Input 5

29 Digital Input 6

Terminal 27 default function RUN REVERSE input

Terminal 28 default function Analog INPUT 1 / INPUT 2 select

Terminal 29 default function JOG SELECT input

Type Negative or positive logic digital inputs Logic mode controlled by... Pr 8.29 Voltage range 0V to +24V Absolute maximum applied voltage

range Impedance Input thresholds 10.0V ±0.8V

Sample / Update period

±30V

250

μs with destinations as Pr 6.35 or

Pr 6.36. 600 4ms in all other cases.

μs with destinations as Pr 6.29.

30 0V common

Function

Common connection for all external devices

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Drive encoder connector

Female 15-way D-type

Information

Type Positive logic only digital input Voltage range 0V to +24V Absolute maximum applied voltage ±30V Thresholds 15.5V ±2.5V

Response time

Introduction

Drive enable (SAFE TORQUE OFF (SECURE DISABLE)

function)

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Nominal: 8ms Maximum: 20ms

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The drive enable terminal (T31) provides a SAFE TORQUE OFF (SECURE DISABLE) function. The SAFE TORQUE OFF (SECURE DISABLE) function meets the requirements of EN954-1 category 3 for the prevention of unexpected starting of the drive. It may be used in a safety-related application in preventing the drive from generating torque in the motor to a high level of integrity.

Refer to section 6.19 SAFE TORQUE OFF (SECURE DISABLE) on page 99 for further information.

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6.18 Encoder connections

Figure 6-44 Location of encoder connector

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Relay contacts

Default function

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

Contact maximum current rating

Contact minimum recommended rating

Contact type Normally open Default contact condition Closed when power applied and drive OK Update period 4ms

Drive OK indicator

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

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

12V 100mA

A fuse or other over-current protection should be installed in the relay circuit.

Table 6-29 Encoder types

Setting of

Pr 3.38

(0)

(1)

(2)

Quadrature incremental encoder with or without marker pulse

Incremental encoder with frequency pulses and direction, with or without marker pulse

Incremental encoder with forward pulses and reverse pulses, with or without marker pulse

Description

Quadrature incremental encoder with UVW commutation

Ab.SErVO

(3)

signals, with or without marker pulse Encoder with UVW commutation signals only (Pr 3.34 set to zero)*

Fd.SErVO

(4)

Fr.SErVO

(5)

(6)

SC.HiPEr

(7)

EndAt

(8)

SC.EndAt

(9)

SSI

(10)

SC.SSI

(11)

Incremental encoder with frequency pulses and direction with commutation signals**, with or without marker pulse

Incremental encoder with forward pulses and reverse pulses with commutation signals**, with or without marker pulse

SinCos encoder without serial communications

Absolute SinCos encoder with HiperFace serial communications protocol (Stegmann)

Absolute EndAt serial communications encoder (Heidenhain)

Absolute SinCos encoder with EnDat serial communications protocol (Heidenhain)

Absolute SSI only encoder

Absolute SinCos encoder with SSI

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

** The U, V & W commutation signals are required with an incremental type encoder when used with a servo motor. The UVW commutation signals are used to define the motor position during the first 120

electrical

rotation after the drive is powered-up or the encoder is initialized.

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Table 6-30 Drive encoder connector details

Setting of Pr 3.38

Ter min al

1AFF A F F Cos

(0)

(1)

(2)

Ab.SErVO

(3)

Fd.SErVO

(4)

Fr.SErVO

(5)

(6)

SC.HiPEr

(7)

EndAt

(8)

SC.EndAt

(9)

SSI

(10)

Cos Cos 2 A\ F\ F\ A\ F\ F\ Cosref Cosref Cosref 3 B D R B D R Sin Sin Sin 4 B\ D\ R\ B\ D\ R\ Sinref Sinref Sinref 5Z*

Encoder input - Data (input/output)

6 Z\* Encoder input - Data\ (input/output)

Simulated encoder

Aout, Fout**

Simulated encoder

Aout\, Fout\**

Simulated encoder

Bout, Dout**

Simulated encoder

Bout\, Dout\**

Simulated encoder

Aout, Fout**

Simulated encoder

Aout\, Fout\**

Simulated encoder

Bout, Dout**

Simulated encoder

Bout\, Dout\**

W Encoder input - Clock (output) 12 W\ Encoder input - Clock\ (output) 13 +V*** 14 0V common 15 th****

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SC.SSI

(11)

* Marker pulse is optional ** Simulated encoder output only available in open-loop *** The encoder supply is selectable through parameter configuration to

5Vdc, 8Vdc and 15Vdc

**** Terminal 15 is a parallel connection to T8 analog input 3. If this is to

be used as a thermistor input, ensure that Pr 7.15 is set to ‘th.sc’ (7), ‘th’ (8) or ‘th.diSP’ (9).

SSI encoders typically have maximum baud rate of 500kBaud. When a SSI only encoder is used for speed feedback with a closed loop vector or servo motor, a large speed feedback filter (Pr 3.42) is required due to the time taken for the position information to be transferred from the encoder into the drive. The addition of this filter means that SSI only encoders are not suitable for speed feedback in dynamic or high-speed applications.

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6.18.1 Specifications

Feedback device connections

Ab, Fd, Fr, Ab.SErVO, Fd.SErVO and Fr.SErVO encoders

1 Channel A, Frequency or Forward inputs

2 Channel A\, Frequency\ or Forward\ inputs

3 Channel B, Direction or Reverse inputs

4 Channel B\, Direction\ or Reverse\ inputs

Type EIA 485 differential receivers

Maximum input frequency

Line loading <2 unit loads

Line termination components

Working common mode range +12V to –7V

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

5 Marker pulse channel Z

6 Marker pulse channel Z\

7 Phase channel U

8 Phase channel U\

9 Phase channel V

10 Phase channel V\

11 Phase channel W

12 Phase channel W\

Type EIA 485 differential receivers

Maximum input frequency 512kHz

Line loading

Line termination components

Working common mode range +12V to –7V

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

V01.06.01 and later: 500kHz V01.06.00 and earlier: 410kHz

Ω (switchable)

120

±25V

32 unit loads (for terminals 5 and 6) 1 unit load (for terminals 7 to 12)

120

Ω (switchable for terminals 5 and 6,

always in circuit for terminals 7 to 12)

+14V to -9V

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SC, SC.HiPEr, EndAt, SC.EndAt, SSI and SC.SSI encoders

1 Channel Cos*

2 Channel Cosref*

3 Channel Sin*

4 Channel Sinref*

Type Differential voltage

Maximum Signal level

Maximum input frequency See Table 6-31

Maximum applied differential voltage and common mode voltage range

1.25V peak to peak (sin with regard to sinref and cos with regard to cosref)

±4V

For the SinCos encoder to be compatible with Unidrive SPM, the output signals from the encoder must be a 1V peak to peak differential voltage (across Sin to Sinref and Cos to Cosref).

The majority of encoders have a DC offset on all signals. Stegmann encoders typically have a 2.5Vdc offset. The Sinref and Cosref are a flat DC level at 2.5Vdc and the Cos and Sin signals have a 1V peak to peak waveform biased at 2.5Vdc.

Encoders are available which have a 1V peak to peak voltage on Sin, Sinref, Cos and Cosref. This results in a 2V peak to peak voltage seen at the drive's encoder terminals. It is not recommended that encoders of this type are used with Unidrive SPM, and that the encoder feedback signals should meet the above parameters (1V peak to peak).

Resolution: The sinewave frequency can be up to 500kHz but the resolution is reduced at high frequency. Table 6-31 shows the number of bits of interpolated information at different frequencies and with different voltage levels at the drive encoder port. The total resolution in bits per revolution is the ELPR plus the number of bits of interpolated information. Although it is possible to obtain 11 bits of interpolation information, the nominal design value is 10 bits.

* Not used with EndAt and SSI communications only encoders.

Table 6-31 Feedback resolution based on frequency and voltage level

Volt/Freq 1kHz 5kHz 50kHz 100kHz 200kHz 500kHz

1.2 11 11 10 10 9 8

1.0 11 11 10 9 9 7

0.8 10 10 10 9 8 7

0.610109987

0.4999876

5 Data**

6 Data\**

11 Clock***

12 Clock\***

Type EIA 485 differential transceivers

Maximum frequency 2MHz

Line loading

Working common mode range +12V to –7V

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

32 unit loads (for terminals 5 and 6) 1 unit load (for terminals 11 and 12)

±14V

** Not used with SC encoders. *** Not used with SC and SC.HiPEr encoders.

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Frequency slaving outputs (open loop only)

Ab, Fd, Fr, SC, SC.HiPEr, EndAt, SC.EndAt, SSI and SC.SSI encoders

7 Frequency slaving out channel A

8 Frequency slaving out channel A\

9 Frequency slaving out channel B

10 Frequency slaving out channel B\

Type EIA 485 differential transceivers

Maximum output frequency 512kHz

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

Common to all Encoder types

13 Encoder supply voltage

Supply voltage

Maximum output current 300mA for 5V and 8V*

The voltage on terminal 13 is controlled by Pr 3.36. The default for this parameter is 5V (0) but this can be set to 8V (1) or 15V (2). Setting the encoder voltage supply too high for the encoder could result in damage to the feedback device.

The termination resistors must be disabled if the outputs from the encoder are higher than 5V.

14 0V common

±14V

5.15V ±

2%, 8V ±5% or 15V ±5%

200mA for 15V*

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STO can be used to eliminate electro-mechanical contactors, including special safety contactors, which would otherwise be required for safety applications.

Note on response time of SAFE TORQUE OFF (SECURE DISABLE), and use with safety controllers with self-testing outputs (drives with date code P04 and later).

SAFE TORQUE OFF (SECURE DISABLE) has been designed to have a response time of greater than 1ms, so that it is compatible with safety controllers whose outputs are subject to a dynamic test with a pulse width not exceeding 1ms. For applications where a fast-acting disable function is required, please see section section 13.21.10 Fast Disable on page 262.

Note on the use of servo motors, other permanent-magnet motors, reluctance motors and salient-pole induction motors.

When the drive is disabled through SAFE TORQUE OFF (SECURE DISABLE), a possible (although highly unlikely) failure mode is for two power devices in the inverter circuit to conduct incorrectly.

This fault cannot produce a steady rotating torque in any AC motor. It produces no torque in a conventional induction motor with a cage rotor. If the rotor has permanent magnets and/or saliency, then a transient alignment torque may occur. The motor may briefly try to rotate by up to 180° electrical, for a permanent magnet motor, or 90° electrical, for a salient pole induction motor or reluctance motor. This possible failure mode must be allowed for in the machine design.

The design of safety-related control systems must only be done by personnel with the required training and experience.

The STO function will only ensure the safety of a machine if it is correctly incorporated into a complete safety system. The system must be subject to a risk assessment to confirm that the residual risk of an unsafe event is at an acceptable level for the application.

15 Motor thermistor input

This terminal is connected internally to terminal 8 of the signal connector. Connect only one of these terminals to a motor thermistor. Analog input 3 must be in thermistor mode, Pr 7.15 = th.SC (7), th (8) or th.diSP (9).

6.19 SAFE TORQUE OFF (SECURE DISABLE)

The SAFE TORQUE OFF (SECURE DISABLE) (STO) function provides a means for preventing the drive from generating torque in the motor, with a very high level of integrity. It is suitable for incorporation into a safety system for a machine. It is also suitable for use as a conventional drive enable input. The STO function makes use of the special property of an inverter drive with an induction motor, which is that torque cannot be generated without the continuous correct active behaviour of the inverter circuit. All credible faults in the inverter power circuit cause a loss of torque generation.

The STO function is fail-safe, so when the STO input is disconnected the drive will not operate the motor, even if a combination of components within the drive has failed. Most component failures are revealed by the drive failing to operate. STO is also independent of the drive firmware. This meets the requirements of EN954-1 category 3 for the prevention of

operation of the motor. input also meets the requirements of EN 81-1 clause 12.7.3 b) as part of a system for preventing unwanted operation of the motor in a lift

(elevator).

Independent approval has been given by BGIA.

Independent approval of concept has been given by TÜV. Please

consult the separate guide for lift applications for further information.

On drives with date code P04 and later the STO

To maintain category 3 according to EN954-1 environment limits given in section 14.1 Drive on page 263 must be observed.

STO inhibits the operation of the drive, this includes inhibiting braking. If the drive is required to provide both braking and SAFE TORQUE OFF (SECURE DISABLE) in the same operation (e.g. for emergency stop) then a safety timer relay or similar device must be used to ensure that the drive is disabled a suitable time after braking. The braking function in the drive is provided by an electronic circuit which is not fail-safe. If braking is a safety requirement, it must be supplemented by an independent fail-safe braking mechanism.

STO does not provide electrical isolation. The supply to the drive must be disconnected by an approved isolation device before gaining access to power connections.

The following diagrams illustrate how the STO input can be used to eliminate contactors and safety contactors from control systems. Please note these are provided for illustration only, every specific arrangement must be verified for suitability in the proposed application.

In the first example, illustrated in Figure 6-45, the STO function is used to replace a simple power contactor in applications where the risk of injury from unexpected starting is small, but it is not acceptable to rely on the complex hardware and firmware/software used by the stop/start function within the drive.

Unidrive SPM User Guide 99 Issue Number: 3 www.controltechniques.com

Page 100

Safety

Stop

Start

Drive

Enable

K1 (or at drive output)

+24V

Drive

STO

Using contactor

Using SAFE TORQUE OFF

(SECURE DISABLE)

T31

3 ~

Stop

Start

+24V

Stop

Star t

Drive

Enable

+24V

Safety relay

Two-channel interlocks

Reset

K1 K2

3 ~

Stop

Start

Drive

STO

+24V

Safety relay

Interlocks

Reset

Drive run

(Pr )

10.02

Protected wiring (screened or segregated)

3 ~

NOTE

Stop

Star t

Drive

+24V

Safety relay

Two-channel interlocks

Reset

K1 K2

3 ~

Information

Introduction

Product

Information

System

configuration

Mechanical

Installation

Electrical

Installation

Figure 6-45 Start / stop control EN954-1 category B - replacement

of contactor

In the second example, illustrated in Figure 6-46 and Figure 6-47, a conventional high-integrity system which uses two safety contactors with auxiliary contacts with connected movement is replaced by a single SAFE TORQUE OFF (SECURE DISABLE) system. This arrangement meets EN954-1 category 3.

Figure 6-46 Category 3 interlock using electromechanical safety

contactors

Getting Star ted

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

Figure 6-47 Category 3 interlock using SAFE TORQUE OFF

(SECURE DISABLE) with protected wiring

In the conventional system, a contactor failure in the unsafe direction is detected the next time the safety relay is reset. Since the drive is not part of the safety system it has to be assumed that AC power is always available to drive the motor, so two contactors in series are required in order to prevent the first failure from causing an unsafe event (i.e. the motor driven).

With SAFE TORQUE OFF (SECURE DISABLE) there are no single faults in the drive which can permit the motor to be driven. Therefore it is not necessary to have a second channel to interrupt the power connection, nor a fault detection circuit.

It is important to note that a single short-circuit from the Enable input (STO) to a DC supply of approximately +24V would cause the drive to be enabled. For this reason, Figure 6-47 shows the wire from the Enable input to the safety relay as "protected wiring" so that the possibility of a short circuit from this wire to the DC supply can be excluded, as specified in ISO 13849-2. The wiring can be protected by placing it in a segregated cable duct or other enclosure, or by providing it with a grounded shield. The shield is provided to avoid a hazard from an electrical fault. It may be grounded by any convenient method, no special EMC precautions are required.

If the use of protected wiring is not acceptable, so that the possibility of this short circuit must be allowed for, then a relay must be used to monitor the state of the Enable input, together with a single safety contactor to prevent operation of the motor after a fault. This is illustrated in Figure 6-48.

The auxiliary relay K2 must be located in the same enclosure and close to the drive, with its coil connected as closely as possible to the drive enable (STO) input.

Figure 6-48 Use of contactor and relay to avoid the need for

protected wiring

The safety function of the example circuit is to ensure that the motor does not operate when the interlocks are not signalling a safe state. The safety relay is used to check the two interlock channels and detect faults in those channels. The stop/start buttons are shown for completeness as part of a typical arrangement, they do not carry out a safety function and are not necessary for the safe operation of the circuit

For further applications guidance, refer to the Unidrive SP Advanced User Guide.

100 Unidrive SPM User Guide

www.controltechniques.com Issue Number: 3

Emerson Unidrive SPM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Declaration of Conformity

1 Safety Information

1.1 Warnings, Cautions and Notes

1.2 Electrical safety - general warning

1.4 Environmental limits

1.5 Compliance with regulations

1.6 Motor

1.7 Adjusting parameters

2 Introduction

2.1 Rectifier (SPMC/U)

2.1.1 Half controlled SCR/thyristor rectifier (SPMC)

2.1.2 Diode rectifier (SPMU)

2.2 SPMA inverter

2.3 SPMD inverter

2.4 Input line reactor

2.5 Output sharing choke

2.6 Model number

3 Product Information

3.1 Ratings

3.1.1 Typical short term overload limits

3.2 Operating modes

3.2.1 Open loop mode

3.2.2 RFC mode

3.2.3 Closed loop vector mode

3.2.5 Regen

3.3 Compatible encoders

3.2.4 Servo

3.4 Features

3.5 Nameplate description

3.6 Options

3.7 Items supplied with the drive

4 System configuration

5 Mechanical Installation

5.1 Safety information

5.2 Planning the installation

5.2.1 Access

5.2.2 Environmental protection

5.2.3 Cooling

5.2.4 Electrical safety

5.2.5 Fire protection

5.2.6 Electromagnetic compatibility

5.2.7 Hazardous areas

5.3 Terminal cover removal

5.3.1 Removing the terminal covers

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

5.4 Solutions Module installation/removal

5.5 Mounting of control master/slave pod

5.5.2 Remote mounting control master pod

5.6 Docking a Unidrive SPMC/U to an SPMD

5.6.1 Installing the docking kit

5.7 Mounting methods

5.7.1 Surface mounting

5.7.2 Through-panel mounting

5.7.3 Mounting brackets

5.7.4 Installation of the Unidrive SPM mounting brackets

5.8 Enclosure

5.8.1 Enclosure layout

5.8.2 Enclosure ambient temperature

5.8.3 Altitude derating

5.8.4 Enclosure sizing

5.9 Heatsink fan operation

5.10 Enclosing drive for high environmental protection

5.11 External EMC filter

5.12 Line reactor mounting dimensions

5.12.1 Input line reactors

5.12.2 Output sharing chokes

5.13 Electrical terminals

5.13.1 Location of the power and ground terminals

5.13.2 Terminal sizes and torque settings

5.14 Routine maintenance

6 Electrical Installation

6.1 Power connections

6.1.1 AC and DC connections

6.1.2 Ground connections

6.2 AC supply requirements

6.2.1 Supply types