Nidec DFS, DFS 1, DFS 2 Power Installation Manual

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Power Installation Guide

Freestanding Drives

DFS Series High Power Drive Cubicles

Part Number: 0478-0573-02 Is

sue: 2

Original Instructions

For the purposes of compliance with the EU Machinery Directive 2006/42/EC, the English version of this manual is the Original Instructions. Manuals in other languages are Translations of the Original Instructions.

Documentation

Manuals are available to download from the following locations: http://www.drive-setup.com/ctdownloads

The information contained in this manual is believed to be correct at the time of printing and does not form part of any contract. The manufacturer reserves the right to change the specification of the product and its performance, and the contents of the manual, without notice.

Warranty and Liability

In no event and under no circumstances shall the manufacturer be liable for damages and failures due to misuse, abuse, improper installation, or abnormal conditions of temperature, dust, or corrosion, or failures due to operation outside the published ratings. The manufacturer is not liable for consequential and incidental damages. Contact the supplier of the drive for full details of the warranty terms.

Environmental policy

Control Techniques Ltd operates an Environmental Management System (EMS) that conforms to the International Standard ISO 14001.

Further information on our Environmental Policy can be found at: http://www.drive-setup.com/environment

Restriction of Hazardous Substances (RoHS)

The products covered by this manual comply with European and International regulations on the Restriction of Hazardous Substances including EU directive 2011/65/EU and the Chinese Administrative Measures for Restriction of Hazardous Substances in Electrical and Electronic Products.

Disposal and Recycling (WEEE)

When electronic products reach the end of their useful life, they must not be disposed of along with domestic waste but should be recycled by a specialist recycler of electronic equipment. Control Techniques products are designed to be easily dismantled into their major component parts for efficient recycling. The majority of materials used in the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden crates. Smaller products are packaged in strong cardboard cartons which have a high recycled fibre content. Cartons can be re-used and recycled. Polythene, used in protective film and bags for wrapping the product, can be recycled. When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

REACH legislation

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

Further information on our compliance with REACH can be found at: http://www.drive-setup.com/reach

Registered Office

Nidec Control Techniques Ltd The Gro Newtown Powys SY16 3BE UK

Registered in England and Wales. Company Reg. No. 01236886.

The contents of this publication 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.

Contents

1 Safety information .....................................................................................10

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

1.2 General information ................................................................................................10

1.3 Responsibility .........................................................................................................10

1.4 Compliance with regulations ..................................................................................10

1.5 Electrical hazards ...................................................................................................11

1.6 Stored electrical charge .........................................................................................11

1.7 Mechanical hazards ...............................................................................................11

1.8 Access to equipment ..............................................................................................11

1.9 Environmental limits ...............................................................................................11

1.10 Hazardous environments .......................................................................................11

1.11 Motor ......................................................................................................................12

1.12 Mechanical brake control .......................................................................................12

1.13 Adjusting parameters .............................................................................................12

1.14 Electromagnetic compatibility (EMC) ..................................................................... 12

1.15 Safe Torque Off ......................................................................................................12

2 Product information ..................................................................................13

2.1 Introduction ............................................................................................................ 13

2.2 Model number ........................................................................................................13

2.3 Nameplate description ...........................................................................................15

2.4 Ratings ...................................................................................................................16

2.5 Cubicle features .....................................................................................................18

3 Mechanical installation .............................................................................20

3.1 Safety information ..................................................................................................20

3.2 Planning the installation .........................................................................................22

3.3 Control terminal cover removal ..............................................................................24

3.4 Cubicle Dimensions ...............................................................................................26

3.5 Terminal size and torque settings ..........................................................................27

3.6 Routine maintenance .............................................................................................28

3.7 Cooling fan replacement ........................................................................................28

3.8 Storage ...................................................................................................................29

4 Electrical installation .................................................................................30

4.1 Power connections .................................................................................................31

4.2 Ground connections ...............................................................................................32

4.3 AC Supply requirements ........................................................................................34

4.4 Operation on IT (ungrounded) supplies .................................................................35

4.5 Ground connections ...............................................................................................36

4.6 Upstream protection ...............................................................................................36

4.7 Motor requirements ................................................................................................39

4.8 Output short circuit protection ................................................................................ 39

4.9 Motor overload protection ......................................................................................40

4.10 Motor cables ...........................................................................................................41

4.11 High-capacitance / reduced diameter cables .........................................................42

4.12 Output contactor .....................................................................................................43

4.13 Safe Torque Off ......................................................................................................43

4.14 Braking ...................................................................................................................43

4.15 Ground leakage ......................................................................................................44

4.16 Use of a residual current device (RCD) .................................................................44

4.17 Starts per hour .......................................................................................................44

4.18 Start-up time ...........................................................................................................44

4.19 Motor winding voltage ............................................................................................44

4.20 Star/ Delta motor operation ....................................................................................45

4.21 External 24 V DC Supplies .....................................................................................45

4.22 Electromagnetic compatibility .................................................................................46

DFS1/DFS2 Power Installation Guide

Issue Number: 2

5 Technical data ............................................................................................ 53

5.1 Drive technical data ............................................................................................... 53

DFS1/DFS2 Power Installation Guide Issue Number: 2

EU Declaration of Conformity

1. Product range

Drive Free Standing (DFS).

2. Name and address of the manufacturer

Nidec Netherlands B.V. Kubus 155 3364 DG Sliedrecht Postbus 300 3360 AH Sliedrecht Netherlands

3. Responsibility

This declaration is issued under the sole responsibility of the manufacturer.

4. Object of the declaration

Model No. Interpretation Nomenclature aaaa - DFS b c d e f g h i

aaaa Drive module range Industrial drive = M700, M701, M702. Process drive = F300

DFS Format DFS = Drive Free Standing

b Number of drives 1, 2

c Current rating step Any alphanumeric character: 1 – 9, A – Z

d Voltage rating 4 = 400 V, 6 = 690 V

e World Region E = Europe, A = Americas

f Input circuit N = Rectifier - Single 6 pulse

g Input switch S = Load Switch (Standard)

h Enclosure rating A = IP23 – Air Cooled, C = IP54 – Air Cooled

iOptions

5. Declaration

The object of the declaration is in conformity with the relevant European Union harmonisation legislation.

Low Voltage Directive (2014/35/EU)

Electromagnetic Compatibility Directive (2014/30/EU)

Restriction of Hazardous Substances Directive (2011/65/EU).

6. References to the relevant harmonised standards used

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

EN 61800-5-1:2007+A1:2017

EN 61800-3: 2018

EN 61000-6-2: 2019

The model number may be followed by any combination of 10 digits denoting customer options. The options do not affect the ratings.

Adjustable speed electrical power drive systems - Part 5-1: Safety requirements Electrical, thermal and energy

Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments

6 DFS1/DFS2 Power Installation Guide

Issue Number: 2

7. Responsible person

Jon Holman-White Vice President of Research and Development Nidec Control Techniques Ltd Date: 20th May 2019 Newtown, Powys, UK.

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 installers who are familiar with requirements for safety and EMC. Refer to the Product Documentation. An EMC data sheet is available giving detailed information. The assembler is responsible for ensuring that the product or system complies with all the relevant laws in the country where it is to be used.

DFS1/DFS2 Power Installation Guide 7 Issue Number: 2

EU Declaration of Conformity (Machinery Directive)

1. Product model

Unidrive-M and derivative products incorporating a Safe Torque Off (STO) function when used as a safety component of a machine.

2. Name and address of the manufacturer

Nidec Control Techniques Ltd, The Gro, Newtown, Powys, SY16 3BE, UK

Registered in England and Wales, Company Reg. No. 0126885

Telephone: 00 44 1686 612300

E-mail: marketing.control techniques@mail.nidec.com

Web: www.controltechniques.com

3. This declaration is issued under the sole responsibility of the manufacturer.

4. Object of the declaration

Model No. Interpretation Nomenclature aaaa - bbc ddddde

aaaa Basic series

bb Frame Size 03, 04, 05, 06, 07, 08, 09, 10, 11

c VoltageRating 1 = 100 V, 2 = 200 V, 4 = 400 V, 5 = 575 V, 6 = 690 V

ddddd Current Rating Example 01000 = 100 A

e Drive Format

The model number may be followed by additional characters that do not affect the ratings.

5. The object of the declaration is in conformity with the relevant European Union harmonisation legislation.

Machine Directive (2006/42/EC)

Electromagnetic Compatibility Directive (2014/30/EU)

M600, M700, M701, M702, M708, M709, M750, M751, M753, M754, F300, H300, E200, E300, HS70, HS71, HS72, M000, RECT

A = 6P Rectifier + Inverter with internal choke, D = Inverter, E = 6P Rectifier + Inverter, T = 12P Rectifier + Inverter (external choke)

EC type examination has been carried out by the following notified body:

TUV Rheinland Industries Service GmbH EC type-examination certificate numbers: AM Grauen Stein D-51105 Köln 01/205/5270.02/17 dated 2017-08-28 Germany

Notified body identification number: 0035

Only the Safe Torque Off function may be used for a safety function of a machine. None of the other functions of the drive may be used to carry out a safety function. The object of the declaration is in conformity with the relevant European Union harmonisation legislation.

8 DFS1/DFS2 Power Installation Guide

Issue Number: 2

6. References to the relevant harmonised standards used

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

EN 61800-5-2:2016

EN 61800-5-1:2016 (in extracts)

EN 61800-3: 2004+A1:2012

EN ISO 13849-1:2015

EN 62061:2005 + AC:2010 + A1:2013 + A2:2015

IEC 61508 Parts 1 - 7:2010

Adjustable speed electrical power drive systems - Part 5-2: Safety requirements Functional

Adjustable speed electrical power drive systems - Part 5-1: Safety requirements Electrical, thermal and energy

Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

Safety of Machinery, Safety-related parts of control systems, General principles for design

Safety of Machinery, Functional safety of safety related electrical, electronic and programmable electronic control systems

Functional safety of electrical/electronic/programmable electronic safety-related systems

7. Signed for and behalf of:

Person authorised to complete the technical file:

DoC authorised by:

P. Knight Conformity Engineer

Jon Holman-White Director of Research and Development

Date:

19th November 2018

Place:

Newtown, Powys, UK

DFS1/DFS2 Power Installation Guide 9 Issue Number: 2

1 Safety information

WARNING

CAUT ION

NOTE

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 General information

This guide applies to products which control electric motors either directly (drives) or indirectly (controllers, option modules and other auxiliary equipment and accessories). In all cases the hazards associated with powerful electrical drives are present, and all safety information relating to drives and associated equipment must be observed.

Specific warnings are given at the relevant places in this guide.

Drives and controllers are intended as components for professional incorporation into complete systems. If installed incorrectly they 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 competence. They must read this safety information and this guide carefully.

1.3 Responsibility

It is the responsibility of the installer to ensure that the equipment is installed correctly with regard to all instructions given in this guide. They must give due consideration to the safety of the complete system, so as to avoid the risk of injury both in normal operation and in the event of a fault or of reasonably foreseeable misuse.

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation of the equipment.

1.4 Compliance with regulations

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

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

All machinery to be supplied within the European Union in which this product is used must comply with the following directives:

2006/42/EC Safety of machinery.

2014/30/EU: Electromagnetic Compatibility.

10 DFS1/DFS2 Power Installation Guide

Issue Number: 2

1.5 Electrical hazards

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. Hazardous voltage may be present in any of the following locations:

• AC and DC supply cables and connections

• Output cables and connections

• Many internal parts of the drive, and external option units

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

The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections.

The STOP and Safe Torque Off functions of the drive do not isolate dangerous voltages from the output of the drive or from any external option unit.

The drive must be installed in accordance with the instructions given in this guide. Failure to observe the instructions could result in a fire hazard.

1.6 Stored electrical charge

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

1.7 Mechanical hazards

Careful consideration must be given to the functions of the drive or controller 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.

With the sole exception of the Safe Torque Off function, none of the drive functions must be used to ensure safety of personnel, i.e. they must not be used for safety-related functions.

The Safe Torque Off function 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.

The design of safety-related control systems must only be done by personnel with the required training and experience. The Safe Torque Off 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.

Safety information

Product information Mechanical installation Electrical installation Technical data

1.8 Access to equipment

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

1.9 Environmental limits

Instructions in this guide regarding transport, storage, installation and use of the equipment must be complied with, including the specified environmental limits. This includes temperature, humidity, contamination, shock and vibration. Drives must not be subjected to excessive physical force.

1.10 Hazardous environments

The equipment must not be installed in a hazardous environment (i.e. a potentially explosive environment).

DFS1/DFS2 Power Installation Guide 11 Issue Number: 2

1.11 Motor

The safety of the motor under variable speed conditions must be ensured.

To avoid the risk of physical injury, do not exceed the maximum specified speed of the motor.

Low speeds may cause the motor to overheat because the cooling fan becomes less effective, causing a fire hazard. 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 must not be relied upon. It is essential that the correct value is entered in the Motor Rated Current parameter.

1.12 Mechanical brake control

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

1.13 Adjusting parameters

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

1.14 Electromagnetic compatibility (EMC)

Installation instructions for a range of EMC environments are provided in the relevant Power Installation Guide. If the installation is poorly designed or other equipment does not comply with suitable standards for EMC, the product might cause or suffer from disturbance due to electromagnetic interaction with other equipment. It is the responsibility of the installer to ensure that the equipment or system into which the product is incorporated complies with the relevant EMC legislation in the place of use.

1.15 Safe Torque Off

The Unidrive M700 / M701 has a single channel Safe Torque Off, whereas the Unidrive M702 has a dual channel STO. The Safe Torque Off 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.

Machinery Applications

The Safe Torque Off function has been independently assessed by Notified Body, TüV Rheinland for use as a safety component of a machine:

Prevention of unintended motor operation: The safety function “Safe Torque Off” can be used in applications up to Cat 4, PL e according to EN ISO 13849-1, SIL 3 according to EN 61800-5-2/ EN 62061/ IEC 61508 and in lift applications according to EN 81-1 and EN 81-2.

TüV certificate No. 01.205/5270.02/17

Date: 28-08-2017

For further details consult the M700, M701 M702 Control User Guide, CT part No. 0478-0353-02.

12 DFS1/DFS2 Power Installation Guide

Issue Number: 2

2 Product information

Parallel dr ives

Curre nt Step Volts Circuit Brake

Drive range

Format

Drive Specification

Configuation

Input

swi t ch

Enclosure

rating

Cubicle options code

M70x

DFS194ENS

10000000

Drive range:

M70x Industrial dr ive F300 Process driv e

Free standing drive

Number of parallel dr ives in a cubicle

Current rating step

Supply voltage:

4=400 V; 6=690 V

World region:

E= Europe A = Americas

Input circuit

N = Rectifier Single 6 pulse

Input switch:

S= Load sw itch

Enclosure rating:

A= IP23 B= IP44 - Air inlet grill filter s C= IP54 - Filters, through panel mounted heatskink s, roof mounted exhaust grill W= Water cooled heat exchanger (IP55)

Options (See table 2-1)

2.1 Introduction

This guide provides the information necessary to install the following cubicle models:

DFS 1

DFS 2

This guide focuses on the cubicle power section, for example: electrical installation of the supply / motor cables and mechanical installation of the cubicle.

The drives are housed in a compact IP23 or IP54 enclosure. A water-cooled option is available. A wide range of options are available including EMC filters and kWh meters.

This guide focuses on the drive power section, for example: electrical installation of the supply / motor cables and mechanical installation of the drive.

For information about the cubicle control section, for example: parameter set up information, control and encoder connections please refer to the M700, M701 M702 Control User Guide CT part No. 0478-0353.

2.2 Model number

The model number for the DFS product range is formed as illustrated below:

Figure 2-1 Model numbers

Safety information

Product information

Mechanical installation Electrical installation Technical data

Table 2-1 Options

IP23 A = IP23 (Standard)

IP55 - Water Cooled W = Water cooled heat exchanger

EMC Filter N/A

Remove internal EMC filter Remove internal EMC filter N/A

Remove MOV protection Remove MOV protection N/A

Speed-controlled roof fan Cabinet temperature controlled roof fanN/A

Plinth 200 mm Standard plinth is 100 mm N/A

DFS1/DFS2 Power Installation Guide 13 Issue Number: 2

Option Description Selection Rule

Choose A, B or WIP54 B = IP54

Option Description Selection Rule

NOTE

180° door hinges Alternative hinge for improved access N/A

Cylinder lock with key Extra cubicle security N/A

A - Undervoltage release coil 230 VAC Main switch with 230 VAC (MN)

B - Undervoltage release coil 24 VAC Main switch with 24 VAC (MN)

C - Shunt trip voltage release coil 230 VAC Main switch with 230 VAC (MX)

D - Shunt trip voltage release coil 24 VAC Main switch with 24 VAC (MX)

A - kWh meter Conventional (IP54) with CTs (non MID)

B - kWh meter Modbus RTU with CTs (non MID)

C - kWh meter Profibus (Not available with 690 V)

D - kWh meter Ethernet with CTs (non MID)

kWh meter pulse contacts

24 V back-up supply wiring

Auxiliary contacts main switch

Rittal integrated empty incomer 400 mm

Back plate empty incomer N/A

Emergency stop push button Red push button on door N/A

Air Freight Additional Packaging for DFS1 and 1

with CTs (non MID)

In combination with A, B, C or D kWh meters

Provision for external 24 V backup power supply

Supply and wiring of two auxiliary contacts on main switch

Includes plinth 100 mm both cable plates mounted to DFS

Pallet, Straps, Carton and Labour N/A

If release coil

needed, choose A,

B, C or D

If kWh meter

needed, choose A,

B, C or D

See description

N/A

When ordering a DFS drive, options can be selected using an on-line configurator tool. Alternatively, contact the local Control Techniques drives sales office for further information. The standard options are summarised in Table 2-1.

Cubicle options code is generated by an on-line configurator.

14 DFS1/DFS2 Power Installation Guide

Issue Number: 2

2.3 Nameplate description

DFS model number

Serial number

Unidrive M model number

Input

Voltage/frequency/current

Ouput Voltage/frequency/current

Normal/heavy duty power rating

Figure 2-2 Typical drive rating label

Figure 2-3 Auxiliary supply rating label

Safety information

Product information

Mechanical installation Electrical installation Technical data

Figure 2-4 Upstream protection warning label

DFS1/DFS2 Power Installation Guide 15 Issue Number: 2

2.4 Ratings

NOTE

Table 2-2 400 V and 690 V ratings

Output

power at

400 V

(ND/HD)

Model

Supply voltage

Supply current

Output current

xxxx-DFS1G4EN 400 155 155/134 75/55 100/100 172

xxxx-DFS1H4EN 400 177 184/157 90/75 150/125 202

xxxx-DFS1J4EN 400 232 221/200 110/90 150/150 243

xxxx-DFS1K4EN 400 267 266/224 132/110 200/150 293

xxxx-DFS1L4EN 400 332 320/270 160/132 250/200 352

xxxx-DFS1M4EN 400 397 361/320 200/160 300/250 397

xxxx-DFS1N4EN 400 449 437/377 225/185 350/300 481

xxxx-DFS1P4EN 400 492 487/417 250/200 400/350 536

xxxx-DFS1Q4EN 400 539 507/464 280/250 450/400 558

xxxx-DFS2L4EN 400 631 640/540 320/264 500/400 704

xxxx-DFS2M4EN 400 657 722/640 400/320 600/500 794

xxxx-DFS2N4EN 400 853 874/754 450/370 700/600 962

xxxx-DFS2P4EN 400 935 974/834 500/400 800/700 1072

xxxx-DFS2Q4EN 400 1024 1014/928 560/500 900/800 1116

xxxx-DFS166EN 690 83 86/63 75/55 100/75 95

xxxx-DFS176EN 690 104 108/86 90/75 125/100 119

xxxx-DFS186EN 690 149 125/104 110/90 150/125 138

xxxx-DFS196EN 690 171 155/131 132/110 175/150 171

xxxx-DFS1A6EN 690 202 172/150 160/132 200/175 189

xxxx-DFS1B6EN 690 225 197/178 185/160 250/200 217

xxxx-DFS1C6EN 690 256 225/210 200/185 250/250 248

xxxx-DFS1D6EN 690 302 275/238 250/200 300/250 303

xxxx-DFS1E6EN 690 329 305/263 280/250 400/300 336

xxxx-DFS2A6EN 690 384 344/300 320/264 400/350 378

xxxx-DFS2B6EN 690 427 394/356 370/320 500/400 434

xxxx-DFS2C6EN 690 486 450/420 400/370 500/500 496

xxxx-DFS2D6EN 690 574 550/476 500/400 600/500 606

xxxx-DFS2E6EN 690 625 610/526 560/500 800/600 672

Motor power

at 460 V (ND/HD)

Peak Output

current

xxxx denotes F300, M700, M701 or M702.

Output current and power ratings are shown as Normal Duty/ Heavy Duty For an explanation of Normal and Heavy-Duty ratings, refer to the M700, M701, M702 Control User Guide (CT part number: 0478-0353).

M70x data based on Heavy Duty ratings. F300 data based on Normal Duty ratings.

16 DFS1/DFS2 Power Installation Guide

Issue Number: 2

M70x data based on Heavy Duty ratings. F300 data based on Normal Duty ratings.

NOTE

Table 2-3 Protective ground cable ratings

Input phase conductor size Minimum ground conductor size

> 35 mm² Half of the cross-sectional area of the input phase conductor

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. Typical values are shown in the table below:

Table 2-4 Typical overload limits

Operating mode RFC from cold

Normal Duty overload with motor rated current = drive rated current

Heavy Duty overload with motor rated current = drive rated current

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

175 % for 42 s 175 % for 5 s 150 % for 60 s 150 % for 7 s

RFC 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.

Open loop

from cold

Open loopfrom

100 %

Safety information

Product information

Mechanical installation Electrical installation Technical data

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

Output current

The continuous output current ratings given on the rating label are for maximum 35 °C (95 °F), 1000 m altitude and 2 kHz switching frequency. Derating is required for higher switching frequencies, ambient temperatures > 40 °C (104 °F). For further information, refer to Chapter 5.1 Drive technical data on page 53.

Input current

The input current is affected by the supply voltage and impedance. The input current given on the rating label is the typical input current and is stated for a balanced supply.

DFS1/DFS2 Power Installation Guide 17 Issue Number: 2

2.5 Cubicle features

Figure 2-5 Features of the size 1 cubicle

18 DFS1/DFS2 Power Installation Guide

Issue Number: 2

Figure 2-6 Features of the size 2 cubicle

NOTE

Safety information

Product information

Mechanical installation Electrical installation Technical data

E-plan drawings, which contain parts lists and electrical schematic diagrams for all the DFS frame sizes are available on Support Suite.

DFS1/DFS2 Power Installation Guide 19 Issue Number: 2

3 Mechanical installation

WARNING

CAUT ION

3.1 Safety information

Follow the instructions

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

Stored charge

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 Nidec Industrial Automation or their authorized distributor.

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.

Enclosure

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

Hazardous areas

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

Protection of equipment prior to installation

If the equipment is not to be installed immediately, it must be protected from moisture and dust.

The equipment is delivered wrapped in plastic to protect it from mechanical damage. It is recommended that wrapping is left in place until installation.

20 DFS1/DFS2 Power Installation Guide

Issue Number: 2

3.1.1 Lifting and Handling

NOTE

WARNING

Use the lifting eyebolts attached to the top of the enclosure

Arrow indicates the lifting point/ direction of the enclosure

Insert the shackles into the eyebolts. Ensure the angle of each lifting rope is ≥ 45°

WARNING

The information in this section is also provided on a laminated sheet fixed to the outside of the enclosure. It is intended to be read by the personnel responsible for lifting, handling and transporting the drive.

Lifting and handling

Always lift the drive by the lifting lugs.

The drives are not supplied with lifting lugs. These must be fitted to the top of the enclosure by the installer.

Insert shackles into the eye bolts. Ensure that the angle of each lifting rope is greater than 45°, as shown in Figure 3-1.

Figure 3-1 Lifting the cubicle

Safety information Product information

Mechanical installation

The cubicle is disproportionally heavy at the top and must be properly secured to prevent it from overbalancing and falling during installation.

When transporting the equipment by fork lift truck, place the cubicle on a rigid pallet and secure it in place.

Multiple bayed enclosures cannot be transported this way.

The maximum weight of the cubicles are shown in Table 3-1.

Table 3-1 Maximum cubicle weight

Size Model kg lb

DFS1 All variants 300 661

DFS2 All variants 720 1587

DFS1/DFS2 Power Installation Guide 21 Issue Number: 2

Electrical installation Technical data

Figure 3-2 Transporting the cubicle

NOTE

3.2 Planning the installation

The following considerations must be made when planning the installation:

3.2.1 Access

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

3.2.2 Environmental protection

The DFS drives are offered with a choice of two Ingress Protection (IP) ratings:

IP23: Protection against fingers or similar objects larger than 12.5 mm. Protection from water falling as a spray at any angle up to 60° from the vertical.

IP54: Protection against ingress of dust is not entirely prevented but must not enter in quantities that may interfere with operation of the equipment. Protection from water splashing against the enclosure from any direction.

The drive enclosure protects the internal components from:

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

• Contamination with electrically conductive material

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

• Temperature beyond the specified operating and storage ranges

• Corrosive gasses

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

3.2.3 Cooling

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

3.2.4 Fire protection

The enclosure is classified as a Fire Enclosure within the meaning of IEC 62109-1. It surrounds the internal parts and is intended to minimize the spread of fire or flaming materials from within.

22 DFS1/DFS2 Power Installation Guide

Issue Number: 2

3.2.5 Electromagnetic compatibility

WARNING

CAUT ION

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. For further details relating to EMC, refer to the EMC data sheet, CT part number 0478-0575-01.

3.2.6 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 4 Electrical installation on page 30.

Hot surfaces

Care must be taken when opening the cubicle door as some components may be very hot to touch even after the 10 minutes discharge time.

Safety information Product information

Component IP ratings

The internal cubicle components are rated to IP20. This must be taken into consideration when the doors are opened.

Mechanical installation

Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 23 Issue Number: 2

3.3 Control terminal cover removal

NOTE

3.3.1 Removing the drive control terminal cover

The Unidrive M drive control terminals are fitted with a terminal cover. The terminal cover must be removed to gain access to the control terminals.

Refer to the relevant control user guide for details on the control terminal layout, functionality and option modules.

Figure 3-3 Location and identification of terminal cover

24 DFS1/DFS2 Power Installation Guide

Issue Number: 2

3.3.2 Removal of finger-guard breakouts

WARNING

To remove the finger-guards place the finger-guard on a flat solid surface and knock out the finger guards using a hammer. The breakout can be removed by grasping it with pliers and twisting it off. Once all break-outs have been removed, remove any flash/sharp edges. See Figure 3-4.

Figure 3-4 Removing the finger-guard breakouts

Grommets

Grommets should be installed in the power terminal apertures to help restrict the spread of fire in the event of a major internal failure.

Safety information Product information

Mechanical installation

Table 3.5 Grommet kits

Drive module size Par number Image

Frame size 8 - kit of 8 single entry grommets 3470-0089

Frame size 8- kit of 8 double entry grommets 3470-0090

Frame size 9, 10 and 11 – kit of 8 double entry grommets 3470-0107

DFS1/DFS2 Power Installation Guide 25 Issue Number: 2

Electrical installation Technical data

3.4 Cubicle Dimensions

Figure 3-6 Dimensions of the DFS1 cubicle

Cubicle

type

DFS1 400 600 600 725 2000 100 or 200 180 180 65

Width Depth Height Plinth height Roof fan height

IP23 IP44 IP54 IP23 IP23 IP44 IP54

26 DFS1/DFS2 Power Installation Guide

Issue Number: 2

3.4.1 Cubicle dimensions

Figure 3-7 Dimensions of the DFS2 cubicle

Safety information Product information

Mechanical installation

Cubicle

type

DFS2 1200 600 600 725 2000 100 or 200 180 180 65

Width Depth Height Plinth height Roof fan height

IP23 IP44 IP54 IP23 IP23 IP44 IP54

3.5 Terminal size and torque settings

Table 3-2 Drive control and relay terminal data

Terminal Connection size Torque setting

AC supply M10 lug 15 Nm (11.1 lb ft)

Drive module Motor output terminals 1 x M10 x 17 AF Nut 15 Nm (11.1 lb ft)

Earth (Ground) terminals 1 x M10 x 17 AF Nut 15 Nm (11.1 lb ft)

Output sharing choke bus bar

connections

Mains isolation switch 3 x M10 x 27.5 AF Nut 20 Nm (14.76 lb ft)

Control and user relay terminals Plug-in terminal block 0.5 Nm (0.4lbft)

DFS1/DFS2 Power Installation Guide 27 Issue Number: 2

1 x 11mm hole 10Nm (7.38lbft)

Electrical installation Technical data

Stored charge

WARNING

3.6 Routine maintenance

The cubicle 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 Ensure the enclosure temperature remains at or below maximum specified.

Dust

Moisture Ensure the cubicle shows no signs of condensation.

Enclosure

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

Electrical

Screw connections Ensure all screw terminals remain tight.

Crimp terminals

Cables Check all cables for signs of damage.

Check that the drive module heatsinks and cooling fans are not gathering dust. This includes the roof fans and the filters in the door. The lifetime of the lfan is reduced in dusty environments.

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

3.7 Cooling fan replacement

Refer to the drive module Power Installation guides for details of how to replace the drive module cooling fans in the event of failure.

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3.8 Storage

CAUT ION

The storage conditions are as follows:

Storage temperature: 5 °C to 55 °C

Maximum humidity: 95 % non-condensing at 35 °C.

Maximum storage time: 2 years.

Storage time

Electrolytic capacitors in any electronic product have a finite storage period after which they require reforming or replacing.

The drive modules have a maximum storage time of 2 years, after which the equipment should be powered up for a minimum of 1 hour to reform the capacitors. The equipment can then be stored for a further 2 years.

Safety information Product information

Mechanical installation

DFS1/DFS2 Power Installation Guide 29 Issue Number: 2

Electrical installation Technical data

4 Electrical installation

WARNING

Electric shock risk

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

AC supply cables and connections

DC and brake cables, and connections

Output cables and connections

Many internal parts of the drive, and external option units

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

Isolation device

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

STOP function

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

Safe Torque Off function

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

Stored charge

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

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.

30 DFS1/DFS2 Power Installation Guide

Issue Number: 2

4.1 Power connections

Figure 4-1 DFS1 Power connections

Safety information Product information Mechanical installation Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 31 Issue Number: 2

Figure 4-2 DFS2 power connections

WARNING

4.2 Ground connections

The ground loop impedance must conform to the requirements of local safety regulations. The drive must be grounded by a connection capable of carrying the prospective fault current until the protective device (fuse, etc.) disconnects the AC supply.

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

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

The supply and motor ground connections are made using the ground busbar shown in Figure 4-3 and Figure 4-4.

32 DFS1/DFS2 Power Installation Guide

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Figure 4-3 DFS1 ground connections

Safety information Product information Mechanical installation Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 33 Issue Number: 2

Figure 4-4 DFS2 ground connections

4.3 AC Supply requirements

The DFS drives are suitable for use on any supply type: TN-S, TN-C-S, TT and IT. The AC supply should comply with the limits shown in Table 4-1.

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Table 4-1 AC supply specification

WARNING

Parameter Rating

Voltage 380 V to 480 V ±10 % 500 V to 690 V ±10 %

No of phases 3

Supply frequency 45 to 66 Hz

Supply type TN-S, TN-C-S, TT, IT

Overvoltage category

Impulse voltage rating 4 kV for 400 V, 6 kV for 690 V drives

Maximum supply imbalance

1. For installations where the equipment is installed at the origin of the supply, additional over-voltage suppression (transient voltage surge suppression) must be provided to reduce the overvoltage category from OVC IV to OVC III.

OVC III (according to IEC 60664-1)

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

Auxiliary transformer tap setting

Before powering up the drive, it is important to check that the auxiliary transformer tapping has been set correctly. Wrong selection could result in damage to transformer and the roof fans.

4.4 Operation on IT (ungrounded) supplies

Operation on IT (ungrounded) supplies

Unusual hazards can occur on IT (ungrounded supplies).

A ground (earth) fault in the incoming supply has no effect. The drive will continue to run. However, the phase to phase voltage will appear between two of the supply terminals and ground (Earth). On a 690 V supply, this will stress the insulation.

A ground (earth) fault in the motor circuit may not cause the drive to trip. If the motor is required to continue to run with a ground fault in its circuit, then an input isolating transformer must be provided. If an EMC filter is required, it must be located on the primary side of the isolating transformer.

The following measures must be taken:

Additional, independent motor ground fault protection must be provided.

EMC filters must not be used

The internal EMC filter inside the drive module must be disconnected

1. Disconnection of the internal EMC filter on frame size 11E is only possible at the factory. This must be specified when ordering.

Safety information Product information Mechanical installation Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 35 Issue Number: 2

4.5 Ground connections

WARNING

Ground connections

The equipment must be grounded (earthed). The wiring must conform to local regulations and codes of practice. This is the responsibility of the installer.

The ground loop impedance must conform to the requirements of local safety regulations. The grounded connection must be capable of carrying the prospective fault current until the protective device (fuse, etc.) disconnects the AC supply.

The cross-sectional area of the Ground (Earth) conductor must be not less than half the cross-sectional area of the input phase conductors.

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

Electrochemical corrosion of grounding terminals

Ensure that grounding terminals are protected against corrosion, for example caused by condensation.

4.6 Upstream protection

It is necessary to install upstream fuses to protect the supply cables from overload and fire. The recommended fuse types and current ratings are marked on the Upstream Protection label fixed to the outside of the drive enclosure (See Figure 4-5). Upstream fuse ratings for all DFS drives are shown in Table 4-2. The fuse voltage rating must be suitable for the drive supply voltage.

Figure 4-5 Upstream protection label

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Issue Number: 2

Table 4-2 Upstream fuse ratings

WARNING

NOTE

Model

xxxx-DFS1G4EN 1 155 160 gG 100

xxxx-DFS1H4EN 1 177 200 gG 100

xxxx-DFS1J4EN 1 232 250 gG 100

xxxx-DFS1K4EN 1 267 315 gG 100

xxxx-DFS1L4EN 1 332 400 gG 100

xxxx-DFS1M4EN 1 397 500 gG 100

xxxx-DFS1N4EN 1 449 500 gG 100

xxxx-DFS1P4EN 1 492 630 gG 100

xxxx-DFS1Q4EN 1 539 630 gG 100

xxxx-DFS2L4EN 2 631 800 gG 100

xxxx-DFS2M4EN 2 657 800 gG 100

xxxx-DFS2N4EN 2 853 1000 gG 70

xxxx-DFS2P4EN 2 935 1000 gG 70

xxxx-DFS2Q4EN 2 1024 1250 gG 40

xxxx-DFS166EN 1 83 100 gG 80

xxxx-DFS176EN 1 104 125 gG 80

xxxx-DFS186EN 1 149 160 gG 80

xxxx-DFS196EN 1 171 200 gG 80

xxxx-DFS1A6EN 1 202 250 gG 80

xxxx-DFS1B6EN 1 225 250 gG 80

xxxx-DFS1C6EN 1 256 315 gG 80

xxxx-DFS1D6EN 1 302 315 gG 80

xxxx-DFS1E6EN 1 329 400 gG 100

xxxx-DFS2A6EN 2 384 400 gG 100

xxxx-DFS2B6EN 2 427 500 gG 100

xxxx-DFS2C6EN 2 486 500 gG 100

xxxx-DFS2D6EN 2 574 630 gG 100

xxxx-DFS2E6EN 2 625 800 gG 100

No. of drive

modules fitted

Input current

Upstream

fuse rating

Fuse type

Short circuit

current rating

Safety information Product information Mechanical installation Electrical installation Technical data

Supply cable sizes

Cables sizes must comply with local wiring regulations and are the responsibility of the installer. The cable sizes shown in Table 4-3 and Table 4-4 are for guidance only. The current-carrying capacity of cables is affected by the mounting method and grouping. A larger cable size may be required to avoid excessive temperature or voltage drop.

The cable sizes in Table 4-3 and Table 4-4 are calculated using IEC60364-5-52:2009. table B.52.5, for XLPE or EPR insulation. The cables are assumed to be arranged in a single layer on a perforated horizontal or vertical cable tray system.

DFS1/DFS2 Power Installation Guide 37 Issue Number: 2

A maximum operating ambient temperature of 35 °C is assumed at a maximum altitude of 1000 m and 2 kHz switching frequency. Derating is required for higher switching frequencies, ambient temperatures and altitudes.

Table 4-3 Incoming supply cable sizes and connections

Model

xxxx-DFS1G4EN 155 1 x 50

xxxx-DFS1H4EN 177 1 x 70

xxxx-DFS1J4EN 232 1 x 95

xxxx-DFS1K4EN 267 1 x 95

xxxx-DFS1L4EN 332 1 x 150

xxxx-DFS1M4EN 397 1 x 185

xxxx-DFS1N4EN 449 1 x 240

xxxx-DFS1P4EN 492 2 x 95

xxxx-DFS1Q4EN 539 2 x 120

xxxx-DFS2L4EN 631 2 x 150

xxxx-DFS2M4EN 657 2 x 150

xxxx-DFS2N4EN 853 2 x 240

xxxx-DFS2P4EN 935 3 x 150

xxxx-DFS2Q4EN 1024 3 x 150 NS1250

xxxx-DFS166EN 83 1 x 16

xxxx-DFS176EN 104 1 x 25

xxxx-DFS186EN 149 1 x 50

xxxx-DFS196EN 171 1 x 50

xxxx-DFS1A6EN 202 1 x 70

xxxx-DFS1B6EN 225 1 x 95

xxxx-DFS1C6EN 256 1 x 95

xxxx-DFS1D6EN 302 1 x 120

xxxx-DFS1E6EN 329 1 x 150

xxxx-DFS2A6EN 384 1 x 185

xxxx-DFS2B6EN 427 1 x 240

xxxx-DFS2C6EN 486 2 x 95

xxxx-DFS2D6EN 574 2 x 120

xxxx-DFS2E6EN 625 2 x 150 NS800

Input

current

Cable size

(mm²)

Incomer switch

MCCB type

(Schneider)

NSX250

NSX400

NSX630

NS800

NS1000

NSX160

NSX250

NSX400

NSX630

Connection

Bar, with 1 x 9 mm

hole

Bar, with 1 x 11 mm

hole

Bar, with 3 x 11 mm

hole two holes are

usable with large

lugs

Bar, with 1 x 9 mm

hole

Bar, with 1 x 11 mm

hole

Aluminium

connection block

required for supply

voltage > 500 V

Connectable cable

sizes

1 or 2 cables up to

150 mm², with

M8 lug

1 or 2 cables up to

240 mm², with

M10 lug

1 to 4 cables up to

240 mm², with

M10 lug

1 or 2 cable up to

150 mm², with

M8 lug

1 or 2 cables up to

240 mm², with

M10 lug

1 to 4 cable up to

240 mm²,

bare cables

Motor cable sizes

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

The number of cables is always 1 or 2 per installed power module

38 DFS1/DFS2 Power Installation Guide

Issue Number: 2

Table 4-4 Motor output cable sizes and connections

Model

xxxx-DFS1G4EN 150 1 x 50

xxxx-DFS1H4EN 184 1 x 70

xxxx-DFS1J4EN 221 1 x 95

xxxx-DFS1K4EN 266 1 x 95

xxxx-DFS1L4EN 320 1 x 150

xxxx-DFS1M4EN 361 1 x 185

xxxx-DFS1N4EN 437 1 x 240

xxxx-DFS1P4EN 487 2 x 95

xxxx-DFS1Q4EN 507 2 x 95

xxxx-DFS2L4EN 640 2 x 150

xxxx-DFS2M4EN 722 2 x 185

xxxx-DFS2N4EN 874 2 x 240

xxxx-DFS2P4EN 974 3 x 150

xxxx-DFS2Q4EN 1014 3 x 150

xxxx-DFS166EN 86 1 x 16

xxxx-DFS176EN 108 1 x 25

xxxx-DFS186EN 125 1 x 35

xxxx-DFS196EN 155 1 x 50

xxxx-DFS1A6EN 172 1 x 50

xxxx-DFS1B6EN 197 1 x 70

xxxx-DFS1C6EN 225 1 x 95

xxxx-DFS1D6EN 275 1 x 120

xxxx-DFS1E6EN 305 1 x 120

xxxx-DFS2A6EN 344 1 x 150

xxxx-DFS2B6EN 394 1 x 185

xxxx-DFS2C6EN 450 1 x 240

xxxx-DFS2D6EN 550 2 x 120

xxxx-DFS2E6EN 610 2 x 120

Output current

Motor cable

size

(mm²)

Terminals Connection

Drive motor

terminals

Output sharing

choke terminals

Drive module

motor terminals

Output sharing

choke terminals

M10 x 17 AF nut

1 x 11 mm hole

M10 x 17 AF nut

1 x 11 mm hole

Connectable cable

sizes

Maximum crimp

size 2 x 150 mm²

1 or 2 cables,

up to 240 mm²,

with M10 lug

Maximum crimp

size 2 x 150 mm²

1 or 2 cables,

up to 240 mm²,

with M10 lug

Safety information Product information Mechanical installation Electrical installation Technical data

4.7 Motor requirements

No. of phases: 3

Maximum voltage:

400 V drive: 480 V

690 V drive: 690 V

4.8 Output short circuit protection

The drive modules are provided with 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 20 μs. No additional short-circuit protection devices are required. Refer to the Unidrive M700, M701, M702 Control User Guide. CT Part Number: 0478-0353.

DFS1/DFS2 Power Installation Guide 39 Issue Number: 2

4.9 Motor overload protection

WARNING

The drive modules are provided with overload protection for the motor and the motor cable.

For this to be effective, the drive overload protection parameter ‘Rated Current (00.046)’ must be set to the rated motor current as marked on the motor rating plate. For details of how to adjust the drive parameters, refer to the Unidrive M700, M701, M702 Control User Guide. CT Part Number: 0478-0353.

Parameter Pr 00.046 ‘Motor Rated Current’ must be set correctly to avoid a risk of fire in the event of motor overload.

The maximum percentage overload limit depends on the motor and the operating mode. Typical values are shown in Table 4-5.

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

Table 4-5 Typical motor overload limits

Operating mode

Normal Duty overload with motor rated current = drive rated current

Heavy Duty overload with motor rated current = drive rated current

RFC from

cold

110 % fo r

165 s

175 % for 42 s 175 % for 5 s 150 % for 60 s 150 % for 7 s

RFC from

100 %

110% for 9s

Open loop

from cold

110 % f or

165 s

Open loop

from 100 %

110% for 9s

40 DFS1/DFS2 Power Installation Guide

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4.10 Motor cables

Capacitance in the motor cable causes loading on the output of the drive. The loading increases with switching frequency. The maximum recommended motor cable lengths for a range of switching frequencies are shown in Table 4-6.

Table 4-6 Maximum motor cable lengths

Maximum permissible motor cable length for each of the following switching

Model

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

400 V

xxxx-DFS1G4EN

xxxx-DFS1H4EN

xxxx-DFS1J4EN

xxxx-DFS1K4EN

xxxx-DFS1L4EN

xxxx-DFS1M4EN

xxxx-DFS1N4EN 250 m (820 ft)

xxxx-DFS1P4EN 250 m (820 ft)

xxxx-DFS1Q4EN 250 m (820 ft)

xxxx-DFS2L4EN 250 m (820 ft)

xxxx-DFS2M4EN 250 m (820 ft)

xxxx-DFS2N4EN 250 m (820 ft)

xxxx-DFS2P4EN 250 m (820 ft)

xxxx-DFS2Q4EN 250 m (820 ft)

250 m (820 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

frequencies

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

62 m

(203 ft)

46 m

(151 ft)

Safety information Product information Mechanical installation Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 41 Issue Number: 2

Maximum permissible motor cable length for each of the following switching

Normal capacitance

Shield or armor separated from the cores

High capacitance

Shield or armor close to the cores

Model

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

690 V

xxxx-DFS166EN

xxxx-DFS176EN

xxxx-DFS186EN

xxxx-DFS196EN

xxxx-DFS1A6EN

xxxx-DFS1B6EN

xxxx-DFS1C6EN 250 m (820 ft)

xxxx-DFS1D6EN 250 m (820 ft)

xxxx-DFS1E6EN 250 m (820 ft)

xxxx-DFS2A6EN 250 m (820 ft)

xxxx-DFS2B6EN 250 m (820 ft)

xxxx-DFS2C6EN 250 m (820 ft)

xxxx-DFS2D6EN 250 m (820 ft)

xxxx-DFS2E6EN 250 m (820 ft)

250m (820ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

187 m

(614 ft)

frequencies

125 m

(614 ft)

125 m

(614 ft)

125 m

(614 ft)

93 m

(305 ft)

93 m

(305 ft)

93 m

(305 ft)

62 m

(203 ft)

62 m

(203 ft)

62 m

(203 ft)

46 m

(151 ft)

46 m

(151 ft)

46 m

(151 ft)

4.11 High-capacitance / reduced diameter cables

The recommended motor cable has an insulating jacket between the cores and the armour or shield. These cables have low capacitance between each conductor and all other conductors, including the shield (typically 130 pF/m). Cables that do not have an insulating jacket tend to have high capacitance. If a high-capacitance/ reduced diameter cable is used, then the maximum recommended cable length is half that quoted in Table 4-6. (Figure 4-6 shows how to identify the two types of cable).

Figure 4-6 Cable construction influencing the capacitance

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4.12 Output contactor

WARNING

Output contactor

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

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

The recommended motor contactor is the AC3 type.

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

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

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

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear

The Drive Enable terminal (terminal 31 on Unidrive M700 / M701 and terminal 29 on Powerdrive 300) when opened provides a Safe Torque Off function. This can in many cases replace output contactors.

For further information see the Control User Guide.

4.13 Safe Torque Off

The drives are provided with a Safe Torque Off function. In many cases this can replace output contactors.

For further information see the Unidrive M700, M701, M702 Control User Guide. CT Part Number: 0478-0353-02.

Safety information Product information Mechanical installation Electrical installation Technical data

Safe Torque Off does not provide isolation

The Safe Torque Off function does not remove dangerous voltages from the drive and does not isolate the motor output terminals.

4.14 Braking

Braking

The current range of DFS drives are not provided with Braking resistors, cabling or a brake overload protection circuit that disconnects the drive from the supply in the event of an overload or fault.

Contact the supplier of the drive if braking is required.

DFS1/DFS2 Power Installation Guide 43 Issue Number: 2

4.15 Ground leakage

WARNING

NOTE

WARNING

NOTE

Ground leakage

The ground leakage current is > 3.5 mA AC (10 mA DC).

A permanent fixed ground connection must be provided, or other suitable measures taken to prevent a safety hazard occurring if the connection is lost.

Suitable measures include either a fixed ground connection or automatic disconnection of the supply in case of discontinuity of the protective earthing conductor.

4.16 Use of a residual current device (RCD)

There are three common types of ELCB / RCD:

• AC - detects AC fault currents

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

• B - detects AC, pulsating DC and smooth DC fault currents

Type AC should not be used with variable speed drives.

Type A can only be used with single phase drives

Type B is the only type suitable for use with three phase, variable speed drives

RCD types

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

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

4.17 Starts per hour

The number of starts per hour under electronic control is unlimited.

The number of starts per hour caused by interrupting the AC supply is limited to 20 per hour equally spaced (A minimum interval of 3 minutes between successive starts).

4.18 Start-up time

The time from the instant that power is applied to the drive being ready to run the motor is a maximum of 5 seconds

4.19 Motor winding voltage

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

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

44 DFS1/DFS2 Power Installation Guide

Issue Number: 2

Special precautions are recommended if drive is operated with a motor cable length > 10 m under either of the following conditions:

690 Vac supply voltage 400 Vac operation with continuous or very frequent sustained braking and motor cable length

>10m. Under these conditions, it is recommended that an inverter-rated motor be used. Inverter-rated motors use a reinforced insulation system intended by the manufacturer for repetitive fast-rising pulsed voltage operation.

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

4.20 Star/ Delta motor operation

The voltage rating for Star and Delta connections to the motor should always be checked before attempting to run the motor.

The default setting of the motor rated voltage parameter is the same as the drive rated voltage, i.e. 400 V drive 400 V rated voltage.

A typical 3 phase motor would be connected in Star for 400 V operation and in Delta for 230 V operation. However, variations on this principle are common e.g. 690 V Star and 400 V Delta.

Incorrect connection of the windings will cause severe under or over fluxing of the motor. Under-fluxing results in very poor output torque. Over-fluxing leads to motor saturation and overheating.

4.21 External 24 V DC Supplies

4.21.1 Control supply

An external 24 Vdc supply can be connected to control terminals to provide the following functions:

• To supplement the internal 24 V supply when multiple option modules are being used and the

current drawn by the modules is greater than the drive can supply.

• As a back-up power supply to keep the control circuits powered up when the AC power supply is

removed. This allows any fieldbus modules, application modules, encoders or serial

communications to continue to operate.

• To set up the drive using the keypad when the AC power supply is not available. However, the

drive will be in the Under-voltage state unless either line power supply or low voltage DC

operation is enabled, therefore diagnostics may not be possible. (Power down save parameters

are not saved when using the 24 V back-up power supply input). For further information see the Unidrive M700, M701, M702 Control User Guide. CT Part Number:

0478-0353-02.

4.21.2 Backup supply

The power 24 Vdc supply (terminals 51, 52) can be connected to allow the 24 Vdc supply to be used as a backup supply.

If the 24 Vdc backup supply is not connected the message "Waiting For Power System" will be displayed on the keypad and no drive operations are possible.

For further information see the Unidrive M700, M701, M702 Control User Guide. CT Part Number: 0478-0353-02.

Safety information Product information Mechanical installation Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 45 Issue Number: 2

4.21.3 Heatsink fan supply

CAUT ION

When the drive is operated in low voltage mode, a 24 V supply needs to be provided for the heatsink fan. This should be connected to terminals 61 and 62.

For further information see the Unidrive M700, M701, M702 Control User Guide. CT Part Number: 0478-0353-02.

4.21.4 Low voltage operation

With the addition of a 24 Vdc power supply to supply the control circuits, the drive can operate from a low voltage DC supply with a range from 24 Vdc up to the maximum DC volts. It is possible for the drive to go from operating on a normal line power supply voltage to operating on a much lower supply voltage without interruption. Going from low voltage operation to normal mains operation requires the inrush current to be controlled. This may be provided externally. If not, the drive supply can be interrupted to utilise the normal soft starting method in the drive.

To fully exploit the low voltage mode of operation, the under-voltage level is user programmable.

For more information on how to use this feature, contact the supplier of the drive.

4.22 Electromagnetic compatibility

4.22.1 General requirements for EMC

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.

It is the responsibility of the installer to ensure that the equipment or system into which the product is incorporated complies with the relevant EMC legislation.

If used on a low-voltage public network which supplies domestic premises, then radio frequency interference is to be expected.

Detailed information on EMC compliance is given in the DFS drive EMC Data Sheet, available from the supplier of the drive, CT part number 0478-0575-01.

In the DFS drives, the drive module is mounted on a metal backplate which is safety bonded to the power ground busbar in the enclosure. See Figure 4-7.

46 DFS1/DFS2 Power Installation Guide

Issue Number: 2

Figure 4-7 General EMC enclosure layout showing ground connections

Optional EMC ﬁlter

INL 1

Metal backplate

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

External

controller

0V PE

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

3 phase AC supply ~

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.

Metal backplate safely bonded to the power ground busbar

Optional ground connection

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

Safety information Product information Mechanical installation Electrical installation Technical data

DFS1/DFS2 Power Installation Guide 47 Issue Number: 2

4.22.2 Motor cable

NOTE

Use four core cable to connect the motor to the drive. Connect the ground core of the motor cable to the ground terminal of the motor. See Figure 4-8.

A shielded cable may also be used. The shield of the motor cable should be connected to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50 mm (2 in) long. A full 360° termination of the shield to the terminal housing of the motor is beneficial.

Figure 4-8 Grounding the motor cable shield

4.22.3 Control cables

If the control circuit 0 V must be connected to Ground, this should be done at the system controller to avoid injecting noise into the 0 V circuit.

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

4.22.4 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.

To ensure correct transfer of data, observe the following:

48 DFS1/DFS2 Power Installation Guide

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Resolver connections:

NOTE

• Use a cable with an overall shield and twisted pairs.

• Connect the cable shield to the drive 0 V connection by the shortest possible link.

• It is 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 at this point. The ground connections at both ends should be as

short as possible. If possible, the cable shield should be clamped directly to the resolver body

and to the drive grounding bracket.

• The cable should not be interrupted. If interruptions are unavoidable, ensure that the ground

connections are as short as possible.

Encoder connections:

• Use a cable with the correct impedance.

• Use a cable with an overall shield and twisted pairs.

• Connect the cable shields to 0 V at both the drive and the encoder, using the shortest possible

links.

• The cable should preferably not be interrupted. If interruptions are unavoidable, ensure that the

ground connections are as short as possible. If possible, use a connection method which uses

metallic clamps for the cable shield terminations. The above recommendations apply where the encoder body is isolated from the motor and the encoder circuit is isolated from the encoder body. Where there is no isolation between the encoder circuits and the motor body, the following additional requirement must be observed to give the best

possible noise immunity:

• The shields must be directly clamped to the encoder body and to the drive grounding bracket. This may be achieved by clamping the individual shields or by providing an additional overall shield which is clamped.

The recommendations of the encoder manufacturer must also be followed.

Safety information Product information Mechanical installation Electrical installation Technical data

In order to guarantee maximum noise immunity, double shielded cable 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 enough. In these cases, all the shields should be connected to ground and 0 V at both ends.

If the 0 V is required to be left floating, a cable with individual shields and an overall shield must be used.

Figures 4-9 and 4-10 show 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.

DFS1/DFS2 Power Installation Guide 49 Issue Number: 2

Figure 4-9 Feedback cable – twisted pair

Twis ted

pair

cable

Twisted pair shield

Cable

Cable overall shield

Cable

Cable shield

Twis ted

pair

shield

Cable shield

Twis ted

pair

shield

Connection

at motor

Connection

at drive

Ground clamp on shield

Shield

connection

to 0V

Shield

connection

to 0V

Figure 4-10 Feedback cable connections

4.22.5 Interruptions to the motor cable

The motor cable should ideally be a single length of shielded or armoured cable having no interruptions. In some installations 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 being done on the motor

50 DFS1/DFS2 Power Installation Guide

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Terminal block in the enclosure

From the Drive

To the motor

Back-plate

Enclosure

Isolator

Coupling bar

From the Drive

To the motor

(If required)

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

Figure 4-11 Installing a terminal block in the motor cable

Using a motor isolator/disconnect-switch

The motor cable shields should be connected by a very short conductor having a low inductance.

The use of a flat metal coupling-bar is recommended; conventional wire is not suitable.

The shields should be bonded directly to the coupling-bar using uninsulated metal cable-clamps.

Keep the length of the exposed power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away.

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

Figure 4-12 Connecting the motor cable to an isolator/disconnect switch

Safety information Product information Mechanical installation Electrical installation Technical data

4.22.6 Surge immunity of control circuits

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

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

DFS1/DFS2 Power Installation Guide 51 Issue Number: 2

In applications where they may be exposed to high-energy voltage surges, some special measures

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

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. There is an increased risk when circuits extend outside a building.

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

1. Galvanic isolation, i.e. do not connect the control 0 V terminal to ground. Avoid loops in the control wiring. Ensure that every control wire has its own return (0 V) wire.

2. Shielded cable with additional power ground bonding. The cable shield may be connected to ground at both ends, but in addition the ground conductors at both ends of the cable must be bonded together by a power ground cable (equipotential bonding cable) with cross-sectional area of at least 10 mm², 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 analogue and digital inputs and outputs, a zener diode network or a commercially available surge suppressor may be connected in parallel with the input circuit as shown in Figure 4-13 and Figure 4-14.

If a digital port experiences a severe surge its protective trip may operate (O.L 1 trip code 26). For continued operation after such an event, the trip can be reset automatically by setting parameter Pr 10.034 to 5.

Figure 4-13 Surge suppression for digital and unipolar inputs and outputs

Figure 4-14 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 network.

52 DFS1/DFS2 Power Installation Guide

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5 Technical data

5.1 Drive technical data

5.1.1 Power and current ratings (Derating for switching frequency and temperature)

For a full explanation of ‘Normal Duty’ and ‘Heavy Duty’ refer to the Control User Guide.

Table 5-1 Maximum permissible continuous output current @ 40 °C (104 °F) ambient,

xxxx-DFS1G4EN 155 155 155 151 128 96 73 134 134 125 104 88 71 56

xxxx-DFS1H4EN 184 184 182 158 133 101 73 157 152 138 116 99 77 62

xxxx-DFS1J4EN 221 221 217 184 152 103 73 200 180 177 150 125 88 62

xxxx-DFS1K4EN 221 221 217 184 152 103 73 200 180 177 150 125 88 62

xxxx-DFS1L4EN 320 320 310 272 228 164 118 270 270 265 226 191 139 103

xxxx-DFS1M4EN 352 341 320 273 228 164 119 314 295 271 226 192 139 104

xxxx-DFS1N4EN 437 426 395 317 256

xxxx-DFS1P4EN 475 438 395 317 256 416 398 359 285 234

xxxx-DFS1Q4EN 485 438 395 317 256 441 398 358 285 234

xxxx-DFS2L4EN 608 608 589 517 432 311 224 513 513 503 428 363 264 195

xxxx-DFS2M4EN 669 648 607 518 432 312 226 596 560 514 428 365 264 198

xxxx-DFS2N4EN 830 809 750 602 486

xxxx-DFS2P4EN 902 831 750 602 486 790 755 685 542 445

xxxx-DFS2Q4EN 921 831 750 602 486 838 755 679 542 445

xxxx-DFS166EN 86 86 86 82 69 47 35 63 63 63 62 51 35 27

xxxx-DFS176EN 106 103 99 84 69 47 35 86 86 84 64 51 36 27

xxxx-DFS186EN 125 125 125 120 95 67 51 104 104 104 101 84 58 45

xxxx-DFS196EN 155 155 154 120 95 67 51 131 131 129 101 81 59 45

xxxx-DFS1A6EN 172 172 161 120 95 67 52 150 150 133 101 82 59 45

xxxx-DFS1B6EN 197 197 196 144 107 71 52 178 178 175 131 100 66 48

xxxx-DFS1C6EN 215 215 209

xxxx-DFS1D6EN 263 253 209 238 211 175

xxxx-DFS1E6EN 301 253 209 254 211 175

xxxx-DFS2A6EN 327 327 306 228 180 126 98 285 285 253 191 156 112 85

xxxx-DFS2B6EN 374 374 372 274 205 135 98 338 338 332 249 189 124 91

xxxx-DFS2C6EN 409 409 397

xxxx-DFS2D6EN 499 481 397 452 400 333

xxxx-DFS2E6EN 571 481 397 483 400 333

drive temperature at 45 °C (113 °F)

Maximum permissible continuous output

current (A) for the following switching

Model

kHz3 kHz4 kHz6 kHz8 kHz

frequencies

Maximum permissible continuous output

current (A) for the following switching

kHz

kHz2 kHz3 kHz4 kHz6 kHz8 kHz

400 V

377 377 358 285 234

716 716 679 542 445

690 V

201 205 175

399 390 333

frequencies

kHz

Safety information Product information Mechanical installation Electrical installation

kHz

Technical data

DFS1/DFS2 Power Installation Guide 53 Issue Number: 2

5.1.2 Power dissipation

NOTE

Table 5-2 Losses @ 35°C (95°F) ambient, drive temperature at 40 °C (104 °F)

Normal duty Heavy duty

Model

xxxx-DFS1G4EN 1482 1652 1817 2154 2121 2142 2164 1224 1374 1509 1521 1510 1525 1540

xxxx-DFS1H4EN 1798 2004 2191 2333 2279 2302 2325 1373 1541 1670 1674 1673 1690 1707

xxxx-DFS1J4EN 2431 2710 2989 3075 2992 2842 2833 2132 2136 2370 2492 2475 2501 2538

xxxx-DFS1K4EN 3015 3191 3143 3063 3000 2856 2828 2424 2532 2511 2489 2474 2498 2537

xxxx-DFS1L4EN 3210 3582 3954 4148 4034 3939 3843 2604 2923 3242 3401 3391 3438 3469

xxxx-DFS1M4EN 3703 4121 4226 4154 4038 3947 3874 3166 3376 3393 3398 3419 3442 3485

xxxx-DFS1N4EN 4182 4576 4708 4444 4246

xxxx-DFS1P4EN 4734 4843 4708 4444 4246 3968 4325 4200 3960 3907

xxxx-DFS1Q4EN 4962 4843 4708 4444 4246 4477 4325 4200 3960 3907

xxxx-DFS2L4EN 6032 6382 6286 6126 6000 5712 5656 4848 5064 5022 4978 4948 4996 5074

xxxx-DFS2M4EN 7406 8242 8452 8308 8076 7894 7748 6332 6752 6786 6796 6838 6884 6970

xxxx-DFS2N4EN 8364 9152 9416 8888 8492

xxxx-DFS2P4EN 9468 9686 9416 8888 8492 7936 8650 8400 7920 7814

xxxx-DFS2Q4EN 9924 9686 9416 8888 8492 8954 8650 8400 7920 7814

xxxx-DFS166EN 1579 1861 2180 2814 2945 2974 3004 1132 1345 1585 2136 2284 2307 2330

xxxx-DFS176EN 2015 2374 2753 2947 2935 2964 2994 1526 1813 2174 2212 2218 2240 2263

xxxx-DFS186EN 1878 2213 2548 3218 3155 3266 3465 1513 1798 2083 2653 2714 2910 3161

xxxx-DFS196EN 2384 2797 3211 3232 3155 3267 3474 1931 2281 2631 2677 2711 2917 3174

xxxx-DFS1A6EN 2420 2882 3270 3083 3052 3192 3472 2042 2441 2604 2571 2648 2876 3128

xxxx-DFS1B6EN 2614 3132 3649 3667 3495 3633 3993 2305 2774 3242 3265 3237 3442 3839

xxxx-DFS1C6EN 3225 3893 4497

xxxx-DFS1D6EN 4023 4640 4497 6470 3865 3814

xxxx-DFS1E6EN 4576 4684 4540 3869 3865 3814

xxxx-DFS2A6EN 4840 5764 6540 6166 6104 6384 6944 4084 4882 5208 5142 5296 5752 6256

xxxx-DFS2B6EN 5228 6264 7298 7334 6990 7266 7986 4610 5548 6484 6530 6474 6884 7678

xxxx-DFS2C6EN 6450 7786 8994

xxxx-DFS2D6EN 8046 9280 8994 6940 7730 7628

xxxx-DFS2E6EN 9152 9368 9080 7738 7730 7628

Drive losses (W) including any current

derating for the given conditions

kHz3 kHz4 kHz6 kHz8 kHz

kHz

400 V

690 V

Drive losses (W) including any current

derating for the given conditions

kHz2 kHz3 kHz4 kHz6 kHz8 kHz

3553 3905 4200 3960 3907

7106 7810 8400 7920 7814

3034 3670 3814

6068 7340 7628

kHz

M70x data based on Heavy Duty ratings. F300 data based on Normal Duty ratings.

54 DFS1/DFS2 Power Installation Guide

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5.1.3 Temperature, humidity and cooling method

Ambient temperature operating range:

5 °C to 35 °C, 40 °C with derate (41 °F to 95 °F).

Output current derating must be applied at ambient temperatures > 40 °C (104 °F). Cooling method: Forced convection Maximum humidity: 95 % non-condensing at 40 °C (104 °F) The cubicle is intended to be installed internally and not outside)

5.1.4 Supply requirements

AC supply voltage:

400 V drive: 380 V to 480 V ±10 %

690 V drive: 500 V to 690 V ±10 % Number of phases: 3

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

Frequency range: 45 to 66 Hz

* With natural cooling.

** With forced cooling = 1 m/s.

5.1.5 Motor requirements

No. of phases:3

Maximum voltage:

400 V drive: 480 V

690 V drive: 690 V

5.1.6 Storage

-40 °C (-40 °F) to +55 °C (131 °F) for long term storage, or to +70 °C (158 °F) for short term

storage.

Storage time is 2 years.

Electrolytic capacitors in any electronic product have a storage period after which they require reforming or replacing.

The DC bus capacitors have a storage period of 10 years.

The low voltage capacitors on the control supplies typically have a storage period of 2 years and are thus the limiting factor.

Low voltage capacitors cannot be reformed due to their location in the circuit and thus may require replacing if the drive is stored for a period of 2 years or greater without power being applied.

It is therefore recommended that drives are powered up for a minimum of 1 hour after every 2 years of storage. This process allows the drive to be stored for a further 2 years.

5.1.7 Altitude

Altitude range: 0 to 1,000 m (3,281 ft).

5.1.8 IP / Rating

The cubicle has three IP ratings, IP23, IP54 and IP55.

The IP rating of a product is a measure of protection against ingress and contact to foreign bodies and water. It is stated as IP XX, where the two digits (XX) indicate the degree of protection provided as shown in Table 5-3.

Safety information Product information Mechanical installation Electrical installation

Technical data

DFS1/DFS2 Power Installation Guide 55 Issue Number: 2

Table 5-3 IP Rating degrees of protection

First digit Second digit

Protection against foreign bodies and access to hazardous parts

0 Non-protected 0 Non-protected

Protected against solid foreign objects of 50 mm

Ø and greater (back of a hand)

Protected against solid foreign objects of

12.5 mm Ø and greater (finger)

Protected against solid foreign objects of 2.5 mm

Ø and greater (tool)

Protected against solid foreign objects of 1.0 mm

Ø and greater (wire)

5 Dust-protected (wire) 5 Protected against water jets

6 Dust-tight (wire) 6 Protected against powerful water jets

7- 7

8- 8

Protection against ingress of water

1 Protected against vertically falling water drops

Protected against vertically falling water drops

when enclosure tilted up to 15°

3 Protected against spraying water

4 Protected against splashing water

Protected against the effects of temporary immersion in water

Protected against the effects of continuous immersion in water

5.1.9 Corrosive gasses

Concentrations of corrosive gases must not exceed the levels given in:

• Table A2 of EN 50178:1998

• Class 3C2 of IEC 60721-3-3 This corresponds to the levels typical of urban areas with industrial activities and/or heavy traffic, but not in the immediate neighborhood of industrial sources with chemical emissions.

5.1.10 Start up time

This is the time taken from the moment of applying power to the drive, to the drive being ready to run the motor:

5 seconds

5.1.11 Output frequency / speed range Unidrive Mxxx models:

In open loop mode, the maximum output frequency is limited to 599 Hz. In RFC-A and RFC-S it is limited to 550 Hz.

In RFC-S mode the speed is also limited by the voltage constant (Ke) of the motor unless field weakening operation is enabled. Ke is a specific constant for the servo motor being used. It can normally be found on the motor data sheet in V/k rpm (volts per 1,000 rpm).

It is recommended that a minimum ratio of 12:1 is maintained between the switching frequency and the maximum output frequency to maintain the quality of the output waveform. If this minimum ratio is exceeded, extra motor losses will result due to the increased harmonic content of the output waveform.

5.1.12 Accuracy and resolution Speed:

The absolute frequency and speed accuracy depends on the accuracy of the crystal used with the drive microprocessor. The accuracy of the crystal is 100 ppm, and so the absolute frequency/speed accuracy is 100 ppm (0.01 %) of the reference, when a preset speed is used. If an analog input is used the absolute accuracy is further limited by the absolute accuracy of the analog input.

56 DFS1/DFS2 Power Installation Guide

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The following data applies to the drive only; it does not include the performance of the source of the

WARNING

control signals.

Open loop resolution:

Preset frequency reference: 0.1 Hz

Precision frequency reference: 0.001 Hz

Closed loop resolution:

Preset speed reference: 0.1 rpm

Precision speed reference: 0.001 rpm

Analog input 1: 11 bit plus sign

Analog input 2: 11 bit plus sign

Current:

The resolution of the current feedback is 10 bit plus sign.

Accuracy: typical 2 %

worst case 5 %

5.1.13 Acoustic noise

The acoustic noise levels are as follows:

Minimum speed: 65 dBA

Maximum speed: 86 dBA.

Most of the noise is generated by the roof fan.

5.1.14 Weights

Table 5-4 Overall drive weights

Size Model kg lb

DFS1 All variants 300 661

DFS2 All variants 720 1587

Safety information Product information Mechanical installation Electrical installation

5.1.15 Input current, fuse and cable size ratings

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

Typical input current

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

Maximum continuous input current

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

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

Fuses

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

DFS1/DFS2 Power Installation Guide 57 Issue Number: 2

Technical data

Table 5-5 AC Input current and fuse ratings (400 V)

Typical input

Model

xxxx-DFS1G4EN 137 155 267

xxxx-DFS1H4EN 164 177 303

xxxx-DFS1J4EN 211 232 306

xxxx-DFS1K4EN 245 267 359

xxxx-DFS1L4EN 306 332 445 400 400

xxxx-DFS1M4EN 370 397 523 450 450

xxxx-DFS1N4EN 424 449 579

xxxx-DFS1P4EN 455 492 613

xxxx-DFS1Q4EN 502 539 752 550 550

xxxx-DFS2L4EN 581 631 846 400 400

xxxx-DFS2M4EN 703 754 994 450 450

xxxx-DFS2N4EN 806 853 1100 500 500

xxxx-DFS2P4EN 865 935 1165 500 500

xxxx-DFS2Q4EN 954 1024 1429 550 550

current

AAA

Maximum

continuous

input current

Maximum

overload input

current

Fuse rating

IEC

NominalAMaximum

250 250

315 315

500 500

Table 5-6 AC Input current and fuse ratings (690 V)

Typical input

Model

xxxx-DFS166EN 74 83 121 160 160

xxxx-DFS176EN 92 104 165 160 160

xxxx-DFS186EN 124 149 194 200 200 aR

xxxx-DFS196EN 145 171 226 200 200

xxxx-DFS1A6EN 180 202 268 250 250

xxxx-DFS1B6EN 202 225 313 350 350

xxxx-DFS1C6EN 225 256 379

xxxx-DFS1E6EN 298 329 465

xxxx-DFS2A6EN 342 384 509 250 250 gS

xxxx-DFS2B6EN 384 428 595 350 350 aR

xxxx-DFS2C6EN 428 486 720

xxxx-DFS2E6EN 566 625 884

current

AAA

Maximum

continuous

input current

Maximum

overload input

current

Fuse rating

IEC

NominalAMaximum

500 500xxxx-DFS1D6EN 271 302 425

500 500 aRxxxx-DFS2D6EN 515 574 806

Class

5.1.16 Electromagnetic compatibility (EMC)

This is a summary of the EMC performance of the drive. For full details, refer to the EMC Data Sheet

which can be obtained from the supplier of the drive, CT part number 0478-0575-01.

58 DFS1/DFS2 Power Installation Guide

Issue Number: 2

Table 5-7 Immunity compliance

Standard Type of immunity Test specification Application Level

IEC61000-4-2 EN61000-4-2:2009

IEC61000-4-3 EN61000-43:2006÷A2:2010

IEC61000-4-4 EN61000-4-4:2010

IEC61000-4-5 EN61000-4-5:2014

IEC61000-4-6 EN61000-4-6:2014

IEC61000-4-11 EN61000-4-11:2004

IEC61000-6-1 EN61000-6-1:2007

IEC61000-6-2 EN61000-6-2:2005

IEC61800-3 EN618003:2004÷A1:2012

1. See section section 4.22.6 Surge immunity of control circuits on page 51 for control ports for possible requirements

regarding grounding and external surge protection.

Electrostatic discharge

Radio frequency radiated field

Fast transient burst

Surges

Conducted radio frequency

Voltage dips and interruptions

Generic immunity standard for the residential, commercial and light - industrial environment

Generic immunity standard for the industrial environment

Product standard for adjustable speed power drive systems (immunity requirements)

6 kV contact discharge 8 kV air discharge

10 V/m prior to modulation 80 - 1000 MHz 80 % AM (1 kHz) modulation

5/50 ns 2 kV transient at 5 kHz repetition frequency via coupling clamp

5/50 ns 2 kV transient at 5 kHz repetition frequency by direct injection

Common mode 4 kV

1.2/50 μs waveshape

Differential mode 2kV

1.2/50 μs waveshape

Lines to ground

10 V prior to modulation

0.15 - 80 MHz 80 % AM (1 kHz) modulation

-30 % 10 ms +60 % 100 ms

-60 % 1 s <-95 % 5 s

Module enclosure

Control lines

Power lines

AC supply lines: line to ground

AC supply lines: line to line

Signal ports to

ground

Control and power lines

AC power ports

Meets immunity requirements for first and second environments

Level 3 (industrial)

Level 4 (industrial harsh)

Level 3 (industrial)

Level 4

Level 3

Level 2

Level 3 (industrial)

Complies

Safety information Product information Mechanical installation Electrical installation

Emission

The drive contains an in-built filter for basic emission control. An additional optional external filter provides further reduction of emission. The requirements of the following standards are met, depending on the motor cable length and switching frequency.

DFS1/DFS2 Power Installation Guide 59 Issue Number: 2

Technical data

0478-0573-02

Nidec DFS, DFS 1, DFS 2 Power Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety information

1.1 Warnings, Cautions and Notes

1.2 General information

1.3 Responsibility

1.4 Compliance with regulations

1.5 Electrical hazards

1.6 Stored electrical charge

1.7 Mechanical hazards

1.8 Access to equipment

1.9 Environmental limits

1.10 Hazardous environments

1.11 Motor

1.12 Mechanical brake control

1.13 Adjusting parameters

1.14 Electromagnetic compatibility (EMC)

1.15 Safe Torque Off

2 Product information

2.1 Introduction

2.2 Model number

2.3 Nameplate description

2.4 Ratings

2.5 Cubicle features

3 Mechanical installation

3.1 Safety information

3.2 Planning the installation

3.3 Control terminal cover removal

3.4 Cubicle Dimensions

3.5 Terminal size and torque settings

3.6 Routine maintenance

3.7 Cooling fan replacement

3.8 Storage

4 Electrical installation

4.1 Power connections

4.2 Ground connections

4.3 AC Supply requirements

4.4 Operation on IT (ungrounded) supplies

4.5 Ground connections

4.6 Upstream protection

4.7 Motor requirements

4.8 Output short circuit protection

4.9 Motor overload protection

4.10 Motor cables

4.11 High-capacitance / reduced diameter cables

4.12 Output contactor

4.13 Safe Torque Off

4.14 Braking

4.15 Ground leakage

4.16 Use of a residual current device (RCD)

4.17 Starts per hour

4.18 Start-up time

4.19 Motor winding voltage

4.20 Star/ Delta motor operation

4.21 External 24 V DC Supplies

4.22 Electromagnetic compatibility

5 Technical data

5.1 Drive technical data