Nidec Digitax HD M75, Digitax HD M750 Ethernet, Digitax HD M751 Base, Digitax HD M753 EtherCAT Installation And Technical Manual
Installation and Technical
Guide
Digitax HD
M75X Series
Variable Speed AC drive for Servo and
Induction motors
Part Number: 0478-0395-05
Issue: 5
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.
Copyright
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.
Copyright © June 2018 Nidec Control Techniques Ltd
Contents
1 Safety information .................................6
1.1 Warnings, Cautions and Notes .............................6
1.2 Important safety information. Hazards.
Competence of designers and installers ...............6
1.3 Responsibility ........................................................6
1.4 Compliance with regulations .................................6
1.5 Electrical hazards ..................................................6
1.6 Stored electrical charge ........................................6
1.7 Mechanical hazards ..............................................6
1.8 Access to equipment .............................................6
1.9 Environmental limits ..............................................6
1.10 Hazardous environments ......................................6
1.11 Motor .....................................................................7
1.12 Mechanical brake control ......................................7
1.13 Adjusting parameters ............................................7
1.14 Electromagnetic compatibility (EMC) ....................7
2 Product information ..............................8
2.1 Introduction ...........................................................8
2.2 Model number .......................................................8
2.3 Drive nameplate description .................................9
2.4 Ratings ................................................................10
2.5 Operating modes ................................................11
2.6 Drive features ......................................................12
2.7 Items supplied with the drive ...............................13
2.8 Installation and system accessories ...................14
3 Mechanical installation .......................16
3.1 Safety information ...............................................16
3.2 Planning the installation ......................................16
3.3 SI Option module installation ..............................17
3.4 KI-Compact Display installation ..........................20
3.5 KI-Remote Keypad Adaptor installation ..............21
3.6 Drive dimensions ................................................23
3.7 Ingress protection label .......................................26
3.8 Enclosure layout .................................................27
3.9 Rear venting ........................................................28
3.10 Enclosure sizing ..................................................30
3.11 Enclosure design and drive ambient
temperature .........................................................32
3.12 Drive cooling fan operation .................................32
3.13 Braking resistor ...................................................32
3.14 External EMC filter ..............................................36
3.15 Terminal size and torque settings .......................41
3.16 Hand tools required with Digitax HD M75X
Series ..................................................................42
3.17 Routine maintenance ..........................................42
3.18 Fan replacement .................................................43
4 Electrical installation ..........................47
4.1 Power and ground connections ..........................48
4.2 AC Supply requirements .....................................50
4.3 Supplying the drive with DC ................................51
4.4 External 24 Vdc supply .......................................53
4.5 Low voltage operation .........................................54
4.6 Ratings ................................................................54
4.7 Output circuit and motor protection .....................55
4.8 Braking ................................................................57
4.9 Ground leakage (PE current) ..............................60
4.10 EMC (Electromagnetic compatibility) ..................61
4.11 Control terminals .................................................73
4.12 Position feedback connections ...........................75
4.13 Communication connections ...............................81
4.14 Safe Torque Off (STO) ........................................82
5 Multi axis system design ....................84
5.1 Multi axis system power profile and
configuration .......................................................84
5.2 DC bus paralleling connection method ...............87
5.3 External 24 Vdc supply requirements for
multi axis systems ...............................................90
5.4 Communications link ...........................................91
5.5 Brake operation for multi axis systems ...............91
5.6 EMC filters for multi axis systems .......................91
5.7 Multi axis system installation ...............................92
5.8 Example design of a multi axis system ...............95
6 Technical data .....................................98
6.1 Drive technical data ............................................98
Digitax HD M75X Series Installation and Technical Guide 3
Issue Number: 5
EU Declaration of Conformity
Jonathan Holman-White
Director, Technology
Date: 14th May 2018
Place: Newtown, Powys, UK
Nidec Control Techniques Ltd, The Gro, Newtown, Powys, SY16 3BE, UK.
This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant European
Union harmonization legislation. The declaration applies to the variable speed drive products shown below:
Model number Interpretation Nomenclature aaaa - bbc ddddde
aaaa Basic series
bb Frame size 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, 11
c Voltage rating 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.
The variable speed drive products listed above have been designed and manufactured in accordance with the following European harmonized
standards:
EN 61800-5-1:2007 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements - Electrical, thermal and energy
EN 61800-3: 2004+A1:2012 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods
EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments
EN 61000-6-4: 2007+ A1:2011
EN 61000-3-2:2014
EN 61000-3-3:2013
EN 61000-3-2:2014 Applicable where input current < 16 A. No limits apply for professional equipment where input power 1 kW.
These products comply with the Restriction of Hazardous Substances Directive (2011/65/EU), the Low Voltage Directive (2014/35/EU) and the
Electromagnetic Compatibility Directive (2014/30/EU).
M100, M101, M200, M201, M300, M400, M600, M700, M701, M702, M708, M709, M751, M753, F300, H300,
E200, E300, HS30, HS70, HS71, HS72, M000, RECT
A = 6P Rectifier + Inverter (internal choke), D = Inverter, E = 6P Rectifier + Inverter (external choke),
T = 12P Rectifier + Inverter (external choke)
Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial
environments
Electromagnetic compatibility (EMC) - Part 3-2: Limits for harmonic current emissions (equipment input current
≤16 A per phase)
Electromagnetic compatibility (EMC) - Part 3-3: Limitation of voltage changes, voltage fluctuations and flicker in
public, low voltage supply systems, for equipment with rated current ≤16 A per phase and not subject to
conditional connection
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 end product
or system complies with all the relevant laws in the country where it is to be used.
4 Digitax HD M75X Series Installation and Technical Guide
Issue Number: 5
EU Declaration of Conformity (including 2006 Machinery Directive)
Jonathan Holman-White
Director, Technology
Date: 14th May 2018
Place: Newtown, Powys, UK
Nidec Control Techniques Ltd
The Gro
Newtown
Powys
UK
SY16 3BE
This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant Union
harmonization legislation. The declaration applies to the variable speed drive products shown below:
Model No. Interpretation Nomenclature aaaa - bbc ddddde
aaaa Basic series
bb Frame size 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, 11
c Voltage rating 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.
This declaration relates to these products when used as a safety component of a machine. 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.
These products fulfil all the relevant provisions of the Machinery Directive 2006/42/EC and the Electromagnetic Compatibility Directive (2014/30/EU).
EC type examination has been carried out by the following notified body:
TUV Rheinland Industrie Service GmbH
Am Grauen Stein
D-51105 Köln
Germany
M600, M700, M701, M702, M708, M709, M751, M753, M754, F300, H300, E200, E300, HS70, HS71, HS72,
M000, RECT
A = 6P Rectifier + Inverter (internal choke), D = Inverter, E = 6P Rectifier + Inverter (external choke),
T = 12P Rectifier + Inverter (external choke)
Notified body identification number: 0035
The harmonized standards used are shown below:
EC type-examination certificate numbers:
01/205/5270.02/17 dated 2017-08-28
EN 61800-5-2:2016 Adjustable speed electrical power drive systems - Part 5-2: Safety requirements - Functional
EN 61800-5-1:2016 (in
extracts)
EN 61800-3: 2004+A1:2012 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods
EN ISO 13849-1:2015 Safety of Machinery, Safety-related parts of control systems, General principles for design
EN 62061:2005 + AC:2010
+ A1:2013 + A2:2015
IEC 61508 Parts 1 - 7:2010 Functional safety of electrical/ electronic/programmable electronic safety-related systems
Person authorised to complete the technical file:
P Knight
Conformity Engineer
Newtown, Powys, UK
DoC authorised by:
IMPORTANT NOTICE
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. It is the responsibility of the installer to ensure that the design of the complete
machine, including its safety-related control system, is carried out in accordance with the requirements of the Machinery Directive and any
other relevant legislation. The use of a safety-related drive in itself does not ensure the safety of the machine. Compliance with safety and
EMC regulations depends upon installing and configuring drives correctly, including using the specified input filters. The drive must be
installed only by professional installers who are familiar with requirements for safety and EMC. The assembler is responsible for ensuring
that the end product or system complies with all relevant laws in the country where it is to be used. For more information regarding Safe
Torque Off, refer to the Product Documentation.
Adjustable speed electrical power drive systems - Part 5-1: Safety requirements - Electrical, thermal and energy
Safety of machinery, Functional safety of safety related electrical, electronic and programmable electronic control
systems
Digitax HD M75X Series Installation and Technical Guide 5
Issue Number: 5
Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
WARNING
CAUTION
NOTE
1 Safety information
1.1 Warnings, Cautions and Notes
A Warning contains information which is essential for
avoiding a safety hazard.
A Caution contains information which is necessary for
avoiding a risk of damage to the product or other equipment.
A Note contains information which helps to ensure correct operation of
the product.
1.2 Important safety information. Hazards.
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.
Competence of designers and
installers
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.
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).
6 Digitax HD M75X Series Installation and Technical Guide
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Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
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
this 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.
Digitax HD M75X Series Installation and Technical Guide 7
Issue Number: 5
Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
Identification Label
Electrical Specifications
Derivative
Frame Size:
Voltage Rating:
Current Rating:
Nominal current rating x 10
Power Format:
0
Optional Build
Customer Code
00
A B 1 01
Customer Code :
00 = 50 Hz
Documentation
1
Documentation:
2 - 200 V (200 - 240 ±10 %)
4 - 400 V (380 - 480 ±10 %)
M753 -
01
2
00022
A
Configuration
1
Safety:
1 - Standard
Encode r Interface:
0 - Standard
01 = 60 Hz
Power
Format
Encoder
Interface
Mounting kit and display options:
AB101 - Mounting kit not fitted/
Compact display fitted
(M750, M753)
AB110 - Mounting kit fitted/
Compact display not fitted (M751)
Digitax HD range
Product Line
M751 - Base
M753 - EtherCAT
M750 - Ethernet
01
02
03
2 Product information
The Digitax HD M75X series is a range of high performance servo drives used as a standalone single axis or easily configured for multi-axis systems.
Functionality also allows for this range of drives to be reconfigured for high performance universal AC motor control.
2.1 Introduction
Servo and Universal AC drive
This product family consists of the following variants:
• Digitax HD M750 Ethernet
• Digitax HD M751 Base
• Digitax HD M753 EtherCAT
Common features (Digitax HD M750, M751 and M753)
• Universal high performance open and closed loop control for induction, servo, permanent magnet and linear motors using Unidrive M motor
control algorithms.
• Onboard IEC 61131-3 programmable automation and motion control
• Flexibility with speed and position measurement, supporting multiple devices and all common interfaces
• SD Media Card slot for parameter copying and data storage.
• Dual channel Safe Torque Off (STO) input.
• Simplified wiring and networking for multi-axis arrangements.
• Connect support for quick start commissioning/start up (downloadable from controltechniques.com).
• Option module connectable.
Variant description summary (Digitax HD M750, M751 and M753)
Digitax HD M750 Ethernet
• Ethernet fieldbus communications.
• Integrated 2 port Ethernet switch
Digitax HD M751 Base
• EIA 485 serial communications interface
• Option module support as standard for configuration and flexibility
Digitax HD M753 EtherCAT
• Onboard EtherCAT slave for centralized motion control and accurate synchronization applications.
• 2 integrated EtherCAT ports.
2.2 Model number
The way in which the model numbers for the Digitax HD M75X series product range are formed is illustrated below:
Figure 2-1 Model number
8 Digitax HD M75X Series Installation and Technical Guide
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Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
Model
Frame
size
Drive
format
Input
Output
Voltage
Current
rating
Maximum phase
input current
Output current
23.2
Approvals
Voltage
Frequency
Phases
Maximum phase
input current
Maximum continuous
output current
Voltage
Serial
number
Date code
Model
23.2A
Approvals
0.37kW (0.5 hp)
Key to approvals
CE approval Europe
RCM regulatory
compliance mark
Australia
UL / cUL approval
USA &
Canada
RoHS compliant China
Functional safety
USA &
Canada
Eurasian
conformity
Eurasia
R
NOTE
2.3 Drive nameplate description
The following labels are attached to the drive.
See Figure 2-3 for location of rating labels.
Figure 2-2 Typical drive rating labels
Date code format
The date code is four numbers. The first two numbers indicate the year and the remaining numbers indicate the week of the year in which the drive
was built.
Example:
A date code of 1710 would correspond to week 10 of year 2017.
Digitax HD M75X Series Installation and Technical Guide 9
Issue Number: 5
Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
NOTE
2.4 Ratings
2.4.1 Maximum ratings
The drive ratings given below are for maximum 40 °C (104 °F), 1000 m altitude and 8 kHz switching frequency. Derating is required for higher
switching frequencies, ambient temperature >40 °C (104 °F) and higher altitude. For further information, refer to Chapter 6 Technical data on
page 98.
Table 2-1 Maximum RFC-S mode ratings
Model No. of input phases
01200022 1 1.1 6.6 0.3
01200040 1 2.2 12.0 0.7
01200065 1 3.5 19.5 1.1
02200090 1 5.6 27.0 1.8
02200120 1 7.5 36.0 2.3
03200160 1 10.8 48.0 3.4
01200022 3 2.2 6.6 0.7
01200040 3 4.0 12.0 1.3
01200065 3 6.5 19.5 2.0
02200090 3 9.0 27.0 2.7
02200120 3 12.0 36.0 3.7
03200160 3 16.0 48.0 5.0
01400015 3 1.5 4.5 0.8
01400030 3 3.0 9.0 1.6
01400042 3 4.2 12.6 1.9
02400060 3 6.0 18.0 3.1
02400080 3 8.0 24.0 4.2
02400105 3 10.5 31.5 5.6
03400135 3 13.5 40.5 6.9
03400160 3 16.0 48.0 7.6
Nominal current Peak current Typical continuous output power
AA kW
In continuous applications, the maximum allowed power may override the maximum allowable current.
10 Digitax HD M75X Series Installation and Technical Guide
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Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
2.5 Operating modes
The drive is designed to operate in any of the following modes:
1. RFC - S
With position feedback sensor
Without position feedback sensor (Sensorless)
2. Open loop mode
Open loop vector mode
Fixed V/F mode (V/Hz)
Quadratic V/F mode (V/Hz)
3. RFC - A
With position feedback sensor
Without position feedback sensor (Sensorless)
As a range of high performance servo drives, the Digitax HD M75X series are initially factory configured for RFC-S mode. The operating mode will
need to be re-configured for AC induction motor control (open loop or RFC-A mode).
2.5.1 RFC- S
Rotor Flux Control for Synchronous (permanent magnet brushless) motors (RFC-S) provides closed loop control with position feedback device.
With position feedback
For use with permanent magnet brushless motors with a feedback device installed.
The drive directly controls the speed of the motor using the feedback device to ensure the rotor speed is exactly as demanded.
Absolute position information is required from the feedback device to ensure the output voltage is accurately matched to the back EMF of the motor.
Full torque is available across the entire speed range.
Without position feedback (Sensorless)
For permanent magnet brushless motor control without a feedback device, using current, voltages and key motor parameters for motor control.
2.5.2 Open loop mode
The drive applies power to the motor at frequencies varied by the user. The motor speed is a result of the output frequency of the drive and slip due
to the mechanical load. The drive can improve the speed control of the motor by applying slip compensation. The performance at low speed depends
on whether V/F mode or open loop vector mode is selected.
Open loop vector mode
The voltage applied to the motor is directly proportional to the frequency except at low speed where the drive uses motor parameters to apply the
correct voltage to keep the flux constant under varying load conditions.
Typically 100 % torque is available down to 1 Hz for a 50 Hz motor.
Fixed V/F mode
The voltage applied to the motor is directly proportional to the frequency except at low speed where a voltage boost is provided which is set by the
user. This mode can be used for multi-motor applications.
Typically 100 % torque is available down to 4 Hz for a 50 Hz motor.
Quadratic V/F mode
The voltage applied to the motor is directly proportional to the square of the frequency except at low speed where a voltage boost is provided which is
set by the user. This mode can be used for running fan or pump applications with quadratic load characteristics or for multi-motor applications. This
mode is not suitable for applications requiring a high starting torque.
2.5.3 RFC-A mode
Rotor Flux Control for Asynchronous (induction) motors (RFC-A) encompasses closed loop vector control with a position feedback device.
With position feedback
For use with induction motors with a feedback device installed. The drive directly controls the speed of the motor using the feedback device to ensure
the rotor speed exactly as demanded. Motor flux is accurately controlled at all times to provide full torque all the way down to zero speed.
Without position feedback (Sensorless)
Sensorless mode provides closed loop control without the need for position feedback by using current, voltages and key motor parameters to
estimate the motor speed. It can eliminate instability traditionally associated with open loop control such as operating large motors with light loads at
low frequencies.
Digitax HD M75X Series Installation and Technical Guide 11
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Safety information Product information Mechanical installation Electrical installation Multi axis system design Technical data
1
2
3
7
5
6
8
9
10
11
12
14
13
15
16
17
18
19
4
12
2.6 Drive features
Figure 2-3 Features of the drive (Frame 1 illustrated)
Table 2-2 Key to features of the drive
Number Description
1 Braking terminals
2 AC supply terminals
3 DC bus terminal cover
4 Communication port connections
* Additional mounting frame required when connecting option modules where not already installed.
5 External 24 V supply terminals
6 Status and communication LEDS
7 Reset
8 Display connection
9 SD card slot
10 Control and holding brake terminals
11 Position feedback connection
12 Ground screw
13 Motor terminals
14 Cable screen bracket
15 Option module slot 1 cover*
16 Internal EMC filter screw (frame 1 and 2)
17 DIN rail alignment
18 Option module slot 2 cover*
19 Cooling fan
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2.7 Items supplied with the drive
The drive is supplied with a copy of the Quick Start Guide, a safety information booklet, the Certificate of Quality and supplied accessories including
the items shown in Table 2-3.
Table 2-3 Parts supplied with the drive
Description Frame size 1 and 2 Frame size 3 Quantity
Power Input Connector 1
Brake Connector 1
I/O Connector 1
24 V Supply Input Connector 1
Cable Screen Bracket
Cable Screen Bracket
M4 x 8 Screws (Motor earth, Input earth and
cable screen bracket)
Motor Connector 1
1
1
3
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2
2.8 Installation and system accessories
2.8.1 Installation and system accessory kits available with Digitax HD M75X series
Table 2-4 Options available with drive
Option Part number Description
9500-1050 External DC cable connection kit
9500-1047
9500-1048
82700000020300 KI-Compact 485 adaptor
82700000020400 KI-Compact display
3470-0145 Cable grommet kit
See section 3.14 External
EMC filter on page 36
9500-1053 Fan replacement kit (frame 1 and 2)
9500-1054 Fan replacement kit (frame 3)
4401-0236 Input line choke
Multi axis kit (standard - without SI-Option Mounting kit fitted). Includes DC
busbar, ground screws, 24 V link and communications link.
Multi axis kit (with SI-Option Mounting kit fitted). Includes DC busbar, ground
screws, 24 V link and communications link.
External EMC filter
82700000020200 Encoder breakout kit
9500-1055 SI-Option Mounting kit
4500-0096 USB / EAI485 communications converter cable
3470-0158 Frame 1 Rear vent kit
3470-0181 Frame 2/3 Rear vent kit
82400000019600 KI-Remote Keypad RTC
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Option Part number Description
9500-1049 Compact brake resistor kit, 70 50W (Drive mountable)
1220-2201 External brake resistor - DBR 100 W, 20
1220-2401 External brake resistor - DBR 100 W, 40
1220-2801 External brake resistor - DBR 100 W, 80
2.8.2 Compatible option modules
All standard option modules are color-coded in order to make identification easy. All modules have an identification label on top of the module.
Standard option modules can be installed to any of the available option slots on the drive. The following tables shows the color-code key and gives
further details on their function.
Table 2-5 Option module identification
Typ e
Option
module
*
Color Name Further Details
Fieldbus
Automation
(I/O expansion)
Purple SI-PROFIBUS
Medium Grey SI-DeviceNet
Light Grey SI-CANopen
Beige SI-Ethernet
Yellow Green SI-PROFINET V2
Brown Red SI-EtherCAT
Orange SI-I/O
PROFIBUS option
PROFIBUS adapter for communications with the drive
DeviceNet option
DeviceNet adapter for communications with the drive
CANopen option
CANopen adapter for communications with the drive
External Ethernet module that supports EtherNet/IP, Modbus TCP/IP and
RTMoE. The module can be used to provide high speed drive access, global
connectivity and integration with IT network technologies, such as wireless
networking
PROFINET V2 option
PROFINET V2 adapter for communications with the drive
Note: PROFINET V2 replaces PROFINET RT.
EtherCAT option
EtherCAT adapter for communications with the drive
Extended I/O
Increases the I/O capability by adding the following combinations:
• Digital I/O
• Digital Inputs
• Analog Inputs (differential or single ended)
• Analog Output
• Relays
Light Brown SI-Encoder Incremental encoder input interface module.
Feedback
Dark Brown SI-Universal Encoder
Moss Green MCi200
Automation
(Applications)
Moss Green MCi210
Additional combined encoder input and output interface supporting
Incremental, SinCos, HIPERFACE, EnDAT and SSI encoders.
Machine Control Studio Compatible Applications Processor
2nd processor for running pre-defined and/or customer created application
software.
Machine Control Studio Compatible Applications Processor (with
Ethernet communications)
2nd processor for running pre-defined and/or customer created application
software with Ethernet communications.
* Additional SI option mounting kit required when connecting option modules where not already fitted.
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WARNING
WARNING
WARNING
WARNING
NOTE
3 Mechanical installation
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
The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply has been disconnected. If the drive
has been energized, the AC supply must be isolated at least ten minutes before work may continue.
Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors
may fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals. If the drive has failed in a manner
that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult 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.
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 drive must be protected from:
• Moisture, including dripping water or spraying water and condensation. An anti-condensation heater may be required, which must be switched off
when the drive is running.
• Contamination with electrically conductive material
• Contamination with any form of dust which may restrict the fan, or impair airflow over various components
• Temperature beyond the specified operating and storage ranges
• Corrosive gasses
The product is supplied with a vent cover to prevent debris (e.g. wire off-cuts) from entering the drive. The vent cover must be removed before first
power up.
3.2.3 Cooling
The heat produced by the drive must be removed without its specified operating temperature being exceeded. Refer to section 3.10 Enclosure sizing
on page 30.
3.2.4 Electrical safety
The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 4 Electrical installation on
page 47.
3.2.5 Fire protection
The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided.
For installation in the USA, a NEMA 12 enclosure is suitable.
For installation outside the USA, the following (based on IEC 62109-1, standard for PV inverters) is recommended.
Enclosure can be metal and/or polymeric, polymer must meet requirements which can be summarized for larger enclosures as using materials
meeting at least UL 94 class 5VB at the point of minimum thickness.
Air filter assemblies to be at least class V-2.
The location and size of the bottom shall cover the area shown in Figure 3-1. Any part of the side which is within the area traced out by the 5° angle is
also considered to be part of the bottom of the fire enclosure.
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Drive
5
o
5
o
Notless
tha n 2X
Ba ffle pla tes (m ay b e
above orbelow bottom
of enclosure)
X
Bottom of fire
enclosure
Not less
than 2
times ‘X’
Baffle plates (may be above or
below bottom of enclosure)
Bottom of fire enclosure
X
CAUTION
CAUTION
Figure 3-1 Fire enclosure bottom layout
The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by
having no openings or by having a baffle construction. This means that openings for cables etc. must be sealed with materials meeting the 5VB
requirement, or else have a baffle above. See Figure 3-2 for acceptable baffle construction. This does not apply for mounting in an enclosed electrical
operating area (restricted access) with concrete floor.
Figure 3-2 Fire enclosure baffle construction
3.2.6 Electromagnetic compatibility
Variable speed drives are powerful electronic circuits which can cause electromagnetic interference if not installed correctly with careful attention to
the layout of the wiring.
Some simple routine precautions can prevent disturbance to typical industrial control equipment.
If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions
must be observed. The drive has 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 close to the drives. Space must be made available for the
filters and allowance made for carefully segregated wiring. Both levels of precautions are covered in section 4.10 EMC (Electromagnetic
compatibility) on page 61.
3.2.7 Hazardous areas
The drive must not be located in a classified hazardous area unless it is installed in an approved enclosure and the installation is certified.
3.3 SI Option module installation
Remove the AC/DC power as well as the 24 Vdc supply to the drive before installing / removing the option module. Failure to do so may
result in damage to the product.
Care must be taken when handling the option module interface card to avoid contaminating the gold contacts. Gold contacts must not be
When connecting SI option modules, an additional SI option mounting kit is required, if the drive is not supplied with a SI option mounting kit fitted.
The SI option mounting kit can be ordered from the supplier of the drive. Refer to section 2.8 Installation and system accessories on page 14 for more
information.
For fitting instructions, refer to Figure 3-3.
touched directly, handle the interface card using the protective cover provided in the mounting kit.
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1b
1a
2
3
Figure 3-3 SI Option mounting kit installation
1a. Insert a flat head terminal screwdriver underneath the option module slot covers and prise both out in the direction shown as highlighted (1b).
2. Install the interface cards into the option module slots (do not remove the protective cover); observe correct orientation. The interface card will
remain at an angle with respect to the plastic.
3. Line up and clip the SI option module support mounting frame to the drive in the direction shown.
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2
3
1
NOTE
Figure 3-4 SI Option module installation
1. Remove the protective interface card cover.
2. Align and insert the option module tab into the slot on the drive plastic.
3. Once the option module tab is located into the slot on the drive, push down at the rear of the option module until it clicks into place.
Once fitted, the SI option module remains at an angle with respect to the drive.
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NOTE
1
2
3
3.4 KI-Compact Display installation
The Digitax HD M75X display provides the following features:
• Displays drive status information.
• Allows the drive node address to be set via dials on the front of the display.
• A push button to reset drive trips.
The KI-Compact Display can be installed/removed while the drive is powered. A delay of 10 seconds should be maintained following power up or
following a node address dial adjustment before the KI-Compact Display can be removed from the drive, to ensure correct transfer of node address
data.
lf not already fitted, the display can be ordered from the supplier of the drive. Refer to section 2.8 Installation and system accessories on page 14.
Figure 3-5 Installing the display
1. Align display tether with slot (the tether keeps the display associated to the drive).
2. Slide the display and tether in the direction shown.
3. Push display until it clicks into position.
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1
2
3
4
1. Single Character display.
2. Reset switch.
3. Rotary dial for node address setting (least significant).
4. Rotary dial for node address setting (Most significant).
1
3.4.1 Drive state representation
Figure 3-6 KI-Compact display
Refer to the relevant Digitax HD M75X Control User Guide for more information.
3.5 KI-Remote Keypad Adaptor installation
The Digitax HD M75X Remote Keypad Adaptor provides an EIA-485 port for permanent connection to a KI-Remote Keypad or the temporary
attachment for PC tool connection. The KI-Remote Keypad Adaptor is available from the supplier of the drive. Refer to section 2.8 Installation and
system accessories on page 14.
Figure 3-7 Installing the KI-Remote Keypad Adaptor without display fitted
1. Align the KI-Remote Keypad Adaptor to the display housing and push on until it clicks into place.
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2
3
1
A
B
Figure 3-8 Installing the KI-Remote Keypad Adaptor with KI-Compact Display fitted
1. Unclip and pull the display away from the front cover. The tether keeps the display associated to the drive and should not be removed. A small terminal
screwdriver maybe required to unclip the display. A slot in the drive plastic is provided for this purpose (A).
2. Align the Remote Keypad Adaptor with the display housing noting the position of the notch (See view B above). Install the Remote Keypad Adaptor over the
display tether.
3. Push the Remote Keypad Adaptor into the housing until it clicks into place.
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WARNING
NOTE
40 mm
(1.58 in)
174 mm (6.85 in)
12 mm
(0.47 in)
Æ 5.2 mm
(0.21 in)
28 mm
(1.10 in)
Æ32 mm
(1.26 in)
*
5 mm
(0.20 in)
233 mm (9.17 in)
222 mm (8.74 in)
40 mm (1.58 in)
6 mm
(0.24 in)
Æ 5.2 mm
(0.21 in)
Æ 5.2 mm
(0.21 in)
3.6 Drive dimensions
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.
The drive complies with the requirements of IP20.
The product is designed to fit within a 200 mm (7.87 in) deep cabinet, this may require the use of an angled feedback connector.
3.6.1 Drive dimensions
Figure 3-9 Frame 1 dimensions
* Cut out only required for rear venting; refer to section 3.9 Rear venting on page 28.
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40 mm
(1.58 in)
174 mm (6.85 in)
12 mm
(0.47 in)
278 mm (10.95 in)
267 mm (10.51 in)
Æ 5.2 mm
(0.21 in)
5 mm
(0.20 in)
Æ32 mm
(1.26 in)
*
40 mm (1.58 in)
Æ 5.2 mm
(0.21 in)
6 mm
(0.24 in)
28 mm
(1.10 in)
35 mm
(1.38 in)
Æ 5.2 mm
(0.21 in)
Figure 3-10 Frame 2 dimensions
* Cut outs only required for rear venting; refer to section 3.9 Rear venting on page 28.
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40 mm
(1.58 in)
174 mm (6.85 in)
328 mm (12.91 in)
12 mm
(0.47 in)
Æ 5.2 mm
(0.21 in)
28 mm
(1.10 in)
35 mm
(1.38 in)
Æ32 mm
(1.26 in)
*
317 mm (12.48 in)
5 mm
(0.20 in)
6 mm
(0.24 in)
Æ 5.2 mm
(0.21 in)
40 mm (1.58 in)
Figure 3-11 Frame 3 dimensions
* Cut outs only required for rear venting; refer to section 3.9 Rear venting on page 28.
Mounting screws
For single axis drives stand alone, two M5 screws are required in the top mounting position and one in the lower mounting position.
For multi axis drive mounting, refer to section 5.7 Multi axis system installation on page 92.
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62 mm (2.44 in)
*
1
2
3.6.2 Drive width with option module support installed
Figure 3-12 Drive width with option module support installed
* Allow for up to +0.5 mm tolerance with each drive.
3.7 Ingress protection label
The ingress protection label (shown in Figure 3-13 below) must remain in place while the drive is mounted, and until all enclosure wiring has been
completed. The label should be removed before first power up.
Figure 3-13 Ingress protection label
1. Ingress protection label (Remove before use).
2. Tear off tab (Remove before use).
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³100 mm
(4 in)
Enclosure
³100mm
(4in)
Optional braking resistor and overload
Locate as
Locate optional braking
resistor external to
cubicle (preferably near to or
on top of the cubicle).
Locate the overload protection
device as required
B
B
Ensure minimum clearances
are maintained for the drive
and external EMC filter. Forced
or convection air-flow must not
be restricted by any object or
cabling
Locate as
required
AC supply
contactor and
fuses or MCB
A
External
controller
Signal cables
Plan for all signal cables
to be routed at least
300 mm (12 in) from the
drive and any power cable
NOTE
3.8 Enclosure layout
Please observe the clearances in the diagram below taking into account any appropriate notes for other devices / auxiliary equipment when planning
the installation.
Figure 3-14 Enclosure layout
Table 3-1 Spacing required between drive / enclosure and drive / EMC filter
Drives may be mounted side by side (0 mm).
Drive Size Spacing between EMC filter and drive (A) Spacing between enclosure side wall and drive (B)
All 0 mm (0.00 in) 10 mm (0.39 in)
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1
2
3
4
5
6
1. Rear venting top cover must be fitted.
2. Exhausted air, (rear vent duct)
*.
3. A suitable cubicle vent guard may need to be fitted to maintain the enclosure
IP rating.
4. Enclosure rear panel.
5. Enclosure back plate.
6. Air intake, (cooling fan).
3.9 Rear venting
The rear vent kits allow heated air to be exhausted from the rear of the enclosure via the rear of the drive rather than the top. This feature provides the
following benefits:
• Reduction in enclosure size.
• Allow vertical stacking of drives.
• Reduce the need for a secondary enclosure fan.
Figure 3-15 Rear vent duct (frame 2 illustrated)
* The Frame 1 rear vent kit is supplied with one duct, the frame 2/3 rear vent kit is supplied with two ducts. Refer to section 2.8.1 Installation and
system accessory kits available with Digitax HD M75X series on page 14.
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1
2
3
NOTE
Figure 3-16 Installation of rear vent kit (frame 1 shown)
1. Attach the rear vent top cover to the top of the drive.
2. Align the rear duct tube with the exhaust port; ensure the retaining clips on the tube are vertically aligned. Refer to section 3.6.1 Drive dimensions
on page 23 for duct through hole sizing.
3. Click the duct tube into position on the exhaust port.
The rear duct tube can be cut to length as required.
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³
100mm
(4in)
1
2
1. Enclosure back plate.
2. Enclosure rear panel.
NOTE
A
e
P
kT
intText
–
----------------------------------------
=
For compact multi axis installations, the rear venting kit allows drives to be vertically mounted one above the other, where this is the case, a minimum
clearance of 100 mm (3.94 in) should be maintained between drives.
Figure 3-17 Minimum clearance when vertical mounting
A current derate must be applied to the drive if the rear vent kit is installed. Derating information is provided in section 6.1 Drive technical data on
page 98.
Failure to do so may result in nuisance tripping.
3.10 Enclosure sizing
1. Add the dissipation figures from section 6.1.4 Power dissipation on page 104 for each drive that is to be installed in the enclosure.
2. If an external EMC filter is to be used with each drive, add the dissipation figures from section 6.1.28 EMC filter ratings on page 113 for each
external EMC filter that is to be installed in the enclosure.
3. If the braking resistor is to be mounted inside the enclosure, add the average power figures from for each braking resistor that is to be installed in
the enclosure.
4. Calculate the total heat dissipation (in Watts) of any other equipment to be installed in the enclosure.
5. Add the heat dissipation figures obtained above. This gives a figure in Watts for the total heat that will be dissipated inside the enclosure.
Calculating the size of a sealed enclosure
The enclosure transfers internally generated heat into the surrounding air by natural convection (or external forced air flow); the greater the surface
area of the enclosure walls, the better is the dissipation capability. Only the surfaces of the enclosure that are unobstructed (not in contact with a wall
or floor) can dissipate heat.
Calculate the minimum required unobstructed surface area A
Where:
Unobstructed surface area in m2 (1 m2 = 10.9 ft2)
A
e
T
Maximum expected temperature in °C outside the enclosure
ext
Maximum permissible temperature in °C inside the enclosure
T
int
for the enclosure from:
e
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NOTE
W
H
D
A
e
392.4
5.5 40 30–
---------------------------------
=
W
Ae2HD–
HD+
--------------------------
=
W
7.135 2 2 0.6–
20.6+
-----------------------------------------------------
=
V
3kP
T
intText
–
-------------------------------
=
P Power in Watts dissipated by all heat sources in the enclosure
k Heat transmission coefficient of the enclosure material in W/m
2
/°C
Example
To calculate the size of an enclosure for the following:
• Two drives operating
• External EMC filter for each drive
• Braking resistors are to be mounted outside the enclosure
• Maximum ambient temperature inside the enclosure: 40 °C
• Maximum ambient temperature outside the enclosure: 30 °C
For example, if the power dissipation from each drive is 187 W and the power dissipation from each external EMC filter is 9.2 W.
Total dissipation: 2 x (187 + 9.2) = 392.4 W
Power dissipation for the drives and the external EMC filters can be obtained from Chapter 6 Technical data on page 98.
The enclosure is to be made from painted 2 mm (0.079 in) sheet steel having a heat transmission coefficient of 5.5 W/m
two sides of the enclosure are free to dissipate heat.
The value of 5.5 W/m
doubt, allow for a greater margin in the temperature rise.
Figure 3-18 Enclosure having front, sides and top panels free to dissipate heat
2/o
C. Only the top, front, and
2
/ºC can generally be used with a sheet steel enclosure (exact values can be obtained by the supplier of the material). If in any
Insert the following values:
T
40 °C
int
30 °C
T
ext
k 5.5
P 392.4 W
The minimum required heat conducting area is then:
2
= 7.135 m
(77.8 ft2) (1 m2 = 10.9 ft2)
Estimate two of the enclosure dimensions - the height (H) and depth (D), for instance. Calculate the width (W) from:
Inserting H = 2 m and D = 0.6 m, obtain the minimum width:
= 1.821 m (71.7 in)
If the enclosure is too large for the space available, it can be made smaller only by attending to one or all of the following:
• Using a lower PWM switching frequency to reduce the dissipation in the drives
• Reducing the ambient temperature outside the enclosure, and/or applying forced-air cooling to the outside of the enclosure
• Reducing the number of drives in the enclosure
• Removing other heat-generating equipment
• Using rear vent duct
Calculating the air-flow in a ventilated enclosure
The dimensions of the enclosure are required only for accommodating the equipment. The equipment is cooled by the forced air flow.
Calculate the minimum required volume of ventilating air from:
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P
o
P
l
-------
V
31.3 323.7
40 30–
---------------------------------------
=
WARNING
Where:
V Air-flow in m
T
Maximum expected temperature in °C outside the enclosure
ext
Maximum permissible temperature in °C inside the enclosure
T
int
3
per hour (1 m3/hr = 0.59 ft3/min)
P Power in Watts dissipated by all heat sources in the enclosure
k Ratio of
Where:
P
is the air pressure at sea level
0
is the air pressure at the installation
P
I
Typically use a factor of 1.2 to 1.3, to allow also for pressure-drops in dirty air-filters.
Example
To calculate the size of an enclosure for the following:
• Three drives operating
• External EMC filter for each drive
• Braking resistors are to be mounted outside the enclosure
• Maximum ambient temperature inside the enclosure: 40 °C
• Maximum ambient temperature outside the enclosure: 30 °C
For example, dissipation of each drive: 101 W and dissipation of each external EMC filter: 6.9 W (max).
Total dissipation: 3 x (101 + 6.9) = 323.7 W
Insert the following values:
T
40 °C
int
30 °C
T
ext
k 1.3
P 323.7 W
Then:
= 126.2 m
3
/hr (74.5 ft3 /min) (1 m3/ hr = 0.59 ft3/min)
3.11 Enclosure design and drive ambient temperature
Drive derating is required for operation in high ambient temperatures
Totally enclosing the drive in either a sealed cabinet (no airflow) or in a well ventilated cabinet makes a significant difference on drive cooling.
The chosen method affects the ambient temperature value (T
) which should be used for any necessary derating to ensure sufficient cooling for the
rate
whole of the drive.
The ambient temperature for the four different combinations is defined below:
= T
1. Totally enclosed with no air flow (< 2 m/s) over the drive T
2. Totally enclosed with air flow (> 2 m/s) over the drive T
rate
rate
= T
+ 5 °C
int
int
Where:
= Temperature outside the cabinet
T
ext
= Temperature inside the cabinet
T
int
= Temperature used to select current rating from tables in Chapter 6 Technical data on page 98
T
rate
3.12 Drive cooling fan operation
The drive is ventilated by an internally mounted fan(s).
The drive cooling fan on all sizes is variable speed. The drive controls the speed at which the fan runs based on the drive's thermal model system.
The maximum speed at which the fan operates can be limited in Pr 06.045. This could incur an output current derating. Refer to section 3.18 Fan
replacement on page 43 for information on fan removal.
3.13 Braking resistor
3.13.1 Compact braking resistor
When using the compact brake resistor the drive must be mounted vertically.
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WARNING
1
3
4
B
A
2
The Digitax HD M75X series has been designed with an optional space-saving side mounted braking resistor. The resistor must be installed together
with an SI Option Module Mounting kit. When the compact braking resistor is used, an external thermal protection device is not required as the
resistor is designed such that it will fail safely under any fault conditions. The in-built software overload protection is set-up at default to protect the
resistor.
Table 3-2 Digitax HD M75X series compact braking resistor kit part number
Model size Part number
All 9500-1049
The compact braking resistor must only be used with the Digitax HD M75X drive range.
Figure 3-19 Installing a compact braking resistor
1. Install SI Option module mounting kit.
2. Secure the compact brake assembly to the metal side panel using two M3 mounting screws. Attach and secure the M2 screw (A).
3. Connect the brake resistor cables to terminals BR1 and BR2 on the brake terminal connector.
4. Secure cables to bracket (B).
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WARNING
WARNING
1
2
The M2 screw forms part of the thermal protection system for the compact brake resistor and therefore MUST be fitted. Maximum torque
0.3 N m (2.7 lb in).
3.13.2 External braking resistor
Braking resistor: High temperatures and overload protection
Braking resistors can reach high temperatures. Locate braking resistors so that damage cannot result. Use cable having insulation capable
of withstanding the high temperatures.
External brake resistors are available from Nidec Industrial Automation. They can be mounted in the enclosure as per mounting recommendation in
Figure 3-14 on page 27 using mounting bracket part number 6541-0187 (shown in Figure 3-21). Figure 3-20 below shows the brake resistor mounted
on the mounting bracket. Two M4 screws and nuts (2) can be used to fix the brake resistor to the mounting bracket. One M4 nut with washer (1) is
provided to use for the ground connection. The brake resistor is equipped with a thermal switch, the thermal switch should be integrated in the control
circuit by the user.
Figure 3-20 Brake resistor with the mounting bracket
1. Ground connection (1 x M4 nut and washer).
2. Attaching the brake resistor to the mounting bracket (using 2 x M4 screws and nuts).
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118mm(4.65 in)
15.5mm
(0.61 in)
Æ 4.5mm(0.18 in)
x2holes
1.5mm
(0.06 in)
30.5mm
(1.20 in)
80 mm (3.15 in)
130 mm (5.12 in)
Æ 4.5x6mm(0.18 in)
x2holes
R = 1.5mm
(0.06)
60 mm (2.36 in)
68 mm (2.68 in)
118 m m (4 .65 in)
130 mm (5.12 in)
Æ 4.5mm(0.18 in)
x4holes
15 mm
(0.59 in)
Figure 3-21 Mounting bracket dimensions
Figure 3-22 Brake resistor dimensions
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B
W
C
H
A
D
V
Y
3.14 External EMC filter
3.14.1 Optional external EMC filter dimensions
Figure 3-23 External EMC filter dimensions (4200-3503)
Table 3-3 External EMC filter dimensions (4200-3503)
Part number A B C D H W V Y
4200-3503
99.5 mm
(3.91 in)
51 mm
(2.01 in)
95 mm
(3.74 in)
57.6 mm
(2.27 in)
149.5 mm
(5.89 in)
105 mm
(4.13 in)
M6
6 mm x 4.4 mm
(0.24 x 0.17 in)
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W
C
H
A
D
Y
V
B
Figure 3-24 External EMC filter dimensions (4200-5033)
Table 3-4 External EMC filter dimensions (4200-5033)
Part number ABCDHWVY
4200-5033
180 mm
(7.09 in)
115 m m
(4.53 in)
100 mm
(3.94 in)
60 mm
(2.36 in)
230 mm
(9.06 in)
115 m m
(4.53 in)
M6
6.5 mm
(0.256 in)
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Y
W
C
B
A
H
D
V
Figure 3-25 External EMC filter dimensions (4200-6034)
Table 3-5 External EMC filter dimensions (4200-6034)
Part number ABCDHWVY
4200-6034
140 mm
(5.51 in)
155 mm
(6.10 in)
90 mm
(3.54 in)
100 mm
(3.94 in)
243 mm
(9.57 in)
115 mm
(4.53 in)
M8
5.3 mm
(0.21 in)
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D
H
B
A
C
W
Torque settings of connector = 0.8 N m
Y
Y
Y Y
V V
A
B
H
C
W
D
Figure 3-26 External EMC filter dimensions (4200-6001 and 4200-6002)
Table 3-6 External EMC filter dimensions (4200-6001 and 4200-6002)
Part number A B C D H W Y
4200-6001
4200-6002
304 mm
(11.97 in)
339 mm
13.35 in)
38 mm
(1.50 in)
29 mm
(1.14 in)
359 mm
(14.13 in)
61 mm
(2.40 in)
Figure 3-27 External EMC filter dimensions
5.3 mm
(0.21 in)
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Table 3-7 External EMC filter dimensions
Part
number
4200-1644
4200-8744
4200-3233
4200-5833
4200-5534
4200-7534
4200-0035
Table 3-8 Drive and EMC filter cross reference
200 V
400 V
01400015 to 01400042 3 4200-8744
02400060 to 02400105 3 4200-1644
03400135 to 03400160 3 4200-5833
ABCDHWVY
220 mm
(8.66 in)
160 mm
(6.30 in)
280 mm
(11.02 in)
240 mm
(9.45 in)
220 mm
(8.66 in)
240 mm
(9.45 in)
240 mm
(9.45 in)
Model Number of phases Part number
01200022 1
01200065 1
02200090 1
02200120 1
03200160 1 4200-6034
01200022 3 4200-8744
01200040 3 4200-6002
01200065 3 4200-6001
02200090 3 4200-5833
02200120 3 4200-5833
03200160 3 4200-5833
235 mm
(9.25 in)
180 mm
(7.09 in)
295 mm
(11.61 in)
255 mm
(10.04 in)
235 mm
(9.25 in)
255 mm
(10.04 in)
255 mm
(10.04 in)
25 mm
(0.98 in)
20 mm
(0.79 in)
30 mm
(1.18 in)
30 mm
(1.18 in)
60 mm
(2.36 in)
60 mm
(2.36 in)
65 mm
(2.56 in)
70 mm
(2.76 in)
70 mm
(2.76 in)
85 mm
(3.35 in)
85 mm
(3.35 in)
90 mm
(3.54 in)
135 mm
(5.31 in)
150 mm
(5.91 in)
264 mm
(10.39 in)
204 mm
(8.03 in)
330 mm
(13.00 in)
290 mm
(11.42 in)
298 mm
(11.73 in)
318 mm
(12.52 in)
330 mm
(13.00 in)
45 mm
(1.77 in)
40 mm
(1.57 in)
50 mm
(1.97 in)
50 mm
(1.97 in)
85 mm
(3.35 in)
80 mm
(3.15 in)
90 mm
(3.54 in)
M5 5.4 mm
M5 4.5 mm
M6 5.4 mm
M5 5.4 mm
M6 5.4 mm
M6 6.5 mm
M10 6.5 mm
4200-350301200040 1
4200-5033
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3.14.2 EMC filter torque settings
Table 3-9 Optional external EMC filter terminal data
Part number
4200-3503
4200-5033
4200-6034
4200-6001
4200-6002
4200-1644
4200-8744
4200-3233
4200-5833
4200-5534
4200-7534
4200-0035
Max cable size Recommended torque Ground stud size Max torque
16 mm
16 mm
35 mm
6 mm
6 mm
10 mm
10 mm
16 mm
16 mm
35 mm
35 mm
50 mm
Power connections Ground connections
2
(AWG 6)
2
(AWG 6)
2
(AWG 2)
2
(AWG 10)
2
(AWG 10)
2
(AWG 8)
2
(AWG 8)
2
(AWG 6)
2
(AWG 6)
2
(AWG 2)
2
(AWG 2)
2
(AWG 1/0)
1.5 to 1.8 N m
(13.3 to 15.9 lb in)
1.5 to 1.8 N m
(13.3 to 15.9 lb in)
4 to 4.5 N m
(35.4 to 39.8 lb in)
0.8 N m max
(7.1 lb in max)
0.8 N m max
(7.1 lb in max)
1.5 to 1.8 N m
(13.3 to 15.9 lb in)
1.5 to 1.8 N m
(13.3 to 15.9 lb in)
1.5 to 1.8 N m
(13.3 to 15.9 lb in)
1.5 to 1.8 N m
(13.3 to 15.9 lb in)
4 to 4.5 N m
(35.4 to 39.8 lb in)
4 to 4.5 N m
(35.4 to 39.8 lb in)
7 to 8 N m
(62 to 70.8 lb in)
M6 4 N m (35.4 lb in)
M6 4 N m (35.4 lb in)
M8 9 N m (79.7 Ib in)
M5 2.2 N m (19.5 lb in)
M5 2.2 N m (19.5 lb in)
M6 4 N m (35.4 lb in)
M5 2.2 N m (19.5 lb in)
M6 4 N m (35.4 lb in)
M6 4 N m (35.4 lb in)
M10
15 to 17 N m (132.9 to
150.6 lb in)
3.15 Terminal size and torque settings
Table 3-10 Drive control terminal type
Model Connection type
All Spring terminals
Table 3-11 Drive control terminal data
Terminals Max cable size Min cable size Recommended torque*
Control terminals
+24 V supply connector
* Torque tolerance = 10 %.
Table 3-12 Drive power terminal data
Model size Terminal block description Max cable size Min cable size Recommended torque*
AC power terminal connector
Motor power terminal connector
Brake terminal connector
DC busbar
All
Ground busbar
Internal EMC filter screw
Compact brake resistor mounting
screw
Compact brake resistor thermistor
screw
* Torque tolerance = 10 %.
2
1.5mm
(16 AWG) 0.2 mm2 (24 AWG)
2
6 mm
(10 AWG) 0.5 mm2 (20 AWG)
2
6 mm
(8 AWG) 0.5 mm2 (20 AWG)
2
4 mm
(12 AWG) 0.5 mm2 (20 AWG)
2
6 mm
(8 AWG) 0.5 mm2 (20 AWG)
0.5 N m (4.4 lb in)
0.7 N m (6.2 lb in)
0.5 N m (4.4 lb in)
0.7 N m (6.2 lb in)
2.0 N m (17.7 lb in)
2.0 N m (17.7 lb in)
0.8 N m (7.1 lb in)
0.8 N m (7.1 lb in)
0.3 N m (2.7 lb in)
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3.16 Hand tools required with Digitax HD M75X Series
The following hand tools are required for the setting-up and installation of the drive.
• Torx screwdriver: Size T20 (T10 required for internal EMC filter screw removal and DC terminal cover).
• 2.5 mm flat blade terminal screwdriver.
3.17 Routine maintenance
The drive should be installed in a cool, clean, well ventilated location. Contact of moisture and dust with the drive should be prevented. The routine
maintenance periods outlines in Table 3-13 are dependant upon drive environmental and operational conditions remaining within specifications.
Table 3-13 Recommended routine maintenance
Environment Recommended action Maintenance
Ambient
temperature
Dust
Corrosion Ensure the drive enclosure shows no signs of condensation or corrosion. Annual inspection
Enclosure
Enclosure door
filters
Electrical
Te rm i n al s
Cables Check all cables for signs of damage. Annual inspection
Cooling fan Preventative maintenance check
Ensure enclosure temperature remains at or below maximum specified. Annual inspection
Ensure the drive remains dust free - check that the drive and fan are not gathering dust. The lifetime of
the fan is reduced in dusty environments. Accumulations of dust on the drive or fan assembly should be
removed by vacuuming.
Ensure filters are not blocked and that air is free to flow. Annual inspection
Ensure all screw, nut and crimp terminals remain tight - check for any discoloration which could indicate
overheating.
Annual inspection
Annual inspection
Annual inspection.
Replacement - 6
years
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WARNING
1
A
2
NOTE
3.18 Fan replacement
Electric shock risk
The AC and DC power supply must be disconnected from the drive using an approved isolation device before the fan assembly is removed.
Figure 3-28 Removal of frame size 1 and 2 cooling fan
1. Using a flat bladed tool, press the two tabs inwards to release the fan from the drive frame.
2. Partly withdraw the fan assembly and prise out the two way fan plug from the connector. This should not be performed by pulling on the fan supply
cable. Fully withdraw the fan from the housing.
Accumulations of dust on the drive or fan assembly should be removed by vacuuming.
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1
2
3
NOTE
Figure 3-29 Re-fitting frame 1 and 2 cooling fan assembly
1. To ensure the fan is correctly orientated the airflow direction markings (on the fan) must be positioned as shown in Figure 3-29.
2. Position the fan supply cable so that it sits in the recess between the top of the fan assembly and the plastic housing of the drive.
3. Use a flat bladed tool to fully re-engage the clips into location by pushing on the end of the clips.
Ensure clips are fully engaged in order to prevent air leakage.
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1
2
NOTE
Figure 3-30 Removal of frame size 3 cooling fan
1. Using a flat bladed tool, press the two tabs inwards to release the fan from the drive frame.
2. Partly withdraw the fan assembly and prise out the two way fan plug from the connector. This should not be performed by pulling on the fan supply
cable. Fully withdraw the fans from the housing.
Accumulations of dust on the drive or fan assembly should be removed by vacuuming.
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LABEL
LABEL
1
1
2
Figure 3-31 Re-fitting frame 3 cooling fan assembly
1. For correct orientation, position the fans with the adhesive label and supply cables as shown in Figure 3-31.
2. Use a flat blade tool to fully re-engage the clips into location by pushing on the end of the clips.
Table 3-14 Fan replacement kit
Model Fan part number
Frame size 1 and 2 fan kit 9500-1053
Frame size 3 fan kit 9500-1054
46 Digitax HD M75X Series Installation and Technical Guide
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WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
4 Electrical installation
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
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.
Equipment supplied by plug and socket
Special attention must be given if the drive is installed in equipment which is connected to the AC supply by a plug and socket. The AC
supply terminals of the drive are connected to the internal capacitors through rectifier diodes which are not intended to give safety isolation.
If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically isolating the plug from the
drive must be used (e.g. a latching relay).
Permanent magnet motors
Permanent magnet motors generate electrical power if they are rotated, even when the supply to the drive is disconnected. If that happens
then the drive will become energized through its motor terminals. If the motor load is capable of rotating the motor when the supply is
disconnected, then the motor must be isolated from the drive before gaining access to any live parts.
0V control connections on all frame sizes are internally earthed and cannot be disconnected. Ensure that there is adequate equipotential
bonding between parts of a system with interconnected control wiring.
Digitax HD M75X Series Installation and Technical Guide 47
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L3/N
L2
L1
Input connections
Mains supply
L1 L2
Optional line reactor
Optional
EMC filter
Fuses
L3
BR2
BR1
Optional
braking
resistor
Thermal
overload
protection
device**
Brake connections
-DC
+DC
DC connections
W
V
U
Motor
connections
4.1 Power and ground connections
Figure 4-1 Digitax HD M75X power and ground connections
48 Digitax HD M75X Series Installation and Technical Guide
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NOTE
WARNING
1
2
1. Supply ground connection.
2. Motor ground connection.
4.1.1 Ground connections
The drive must be connected to the system ground of the supply. The ground wiring must conform to local regulations and codes of practice.
For further information on ground cable sizes, refer to Table 4-1 below.
Table 4-1 Protective ground cable ratings
Input phase
conductor size
≤ 10 mm
> 10 mm
2
2
and ≤ 16 mm
Either 10 mm2 or two conductors of the same cross-sectional area as the input phase conductor
2
The same cross-sectional area as the input phase conductor
Minimum ground conductor size
The supply and motor ground connections are made using the M4 threaded holes in the metal side plate of the drive. Connections are located at the
top and bottom of the drive. See Figure 4-2 for details.
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.
Figure 4-2 Supply and motor ground connections
Digitax HD M75X Series Installation and Technical Guide 49
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WARNING
4.2 AC Supply requirements
AC supply voltage:
200 V drive: 200 V to 240 V ±10 %
400 V drive: 380 V to 480 V ±10 %
Number of phases: 1/3
Maximum supply imbalance: 2 % negative phase sequence (equivalent to 3 % voltage imbalance between phases).
Frequency range: 45 to 66 Hz
Table 4-2 Supply fault current used to calculate maximum input currents
Model Symmetrical fault level (kA)
All 100 kA
4.2.1 Supply types
Drives are suitable for use on the following supply types:
Table 4-3 AC supply configuration suitability
AC supply configuration Supply type 230 V 400 V
Any TN, TT or neutral grounded Permitted Permitted
Star (Y) connected supply
Delta connected supply
* 400 V corner grounded delta not supported
Drives are suitable for use on supplies of installation category III and lower, according to IEC 60664-1. This means they may be connected
permanently to the supply at its origin in a building, but for outdoor installation additional over-voltage suppression (transient voltage surge
suppression) must be provided to reduce category IV to category III.
Operation with IT (ungrounded) supplies:
Special attention is required when using internal or external EMC filters with ungrounded supplies, because in the event of a ground (earth)
fault in the motor circuit the drive may not trip and the filter could be over-stressed. In this case, either the filter must not be used (removed)
or additional independent motor ground fault protection must be provided. Refer to Table 4-3. For instructions on removal, refer to
section 4.10.3 Internal EMC filter on page 65. For details of ground fault protection contact the supplier of the drive.
Centre of one side of delta grounded Not permitted Not permitted
IT (floating supply) Permitted Permitted
Corner grounded Not permitted Not permitted
Corner grounded in regen mode Not permitted Not permitted
Any TN, TT or neutral grounded Permitted Not permitted*
IT (floating supply) Permitted Not permitted
Corner grounded in regen mode Not permitted Not permitted
A ground fault in the supply has no effect in any case. If the motor must continue to run with a ground fault in its own circuit then an input isolating
transformer must be provided and if an EMC filter is required it must be located in the primary circuit.
Unusual hazards can occur on ungrounded supplies with more than one source, for example on ships. Contact the supplier of the drive for more
information.
4.2.2 Line reactors
Input line reactors reduce the risk of damage to the drive resulting from poor phase balance or severe disturbances on the supply network.
Where line reactors are to be used, reactance values of approximately 2 % are recommended. Higher values may be used if necessary, but may
result in a loss of drive output (reduced torque at high speed) because of the voltage drop.
For all drive ratings, 2 % line reactors permit drives to be used with a supply imbalance of up to 3.5 % negative phase sequence (equivalent to 5 %
voltage imbalance between phases).
Severe disturbances may be caused by the following factors, for example:
• Power factor correction equipment connected close to the drive.
• Large DC drives having no or inadequate line reactors connected to the supply.
• Direct-on-line started motor(s) connected to the supply such that when any of these motors are started, the voltage dip exceeds 20 %.
Such disturbances may cause excessive peak currents to flow in the input power circuit of the drive. This may cause nuisance tripping, or in extreme
cases, failure of the drive.
Drives of low power rating may also be susceptible to disturbance when connected to supplies with a high rated capacity.
When required, each drive must have its own reactor(s). Three individual reactors or a single three-phase reactor should be used.
Reactor current ratings
Continuous current:
Not less than the continuous input current rating of the drive
Repetitive peak current:
Not less than three times the continuous input current rating of the drive
50 Digitax HD M75X Series Installation and Technical Guide
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L
Y
100
----------
V
3
-------
1
2 f I
------------
=
CAUTION
WARNING
WARNING
1
4.2.3 Input inductor calculation
To calculate the inductance required (at Y %), use the following equation:
Where:
I = drive rated input current (A)
L = inductance (H)
f = supply frequency (Hz)
V = voltage between lines
4.3 Supplying the drive with DC
Contact the supplier of the drive before connecting a Digitax HD M75X series drive to a DC bus supplied from a regenerative drive or AFE
module.
All drive sizes have the option to be powered from an external DC power supply. Refer to section 4.1 Power and ground connections on page 48 to
identify the location of DC supply connections.
4.3.1 DC terminal cover access/removal
Isolation device
The AC and DC power supply must be disconnected from the drive using an approved isolation device before any cover is removed from
the drive or before any servicing work is performed.
Stored charge
The drive contains capacitors that remain charged to a potentially lethal voltage after the AC and/or DC power supply has been
disconnected. If the drive has been energized, the power supply must be isolated at least ten minutes before work may continue.
Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors may
fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals.
The DC supply connections are located under the DC terminal cover.
Figure 4-3 Location of the DC terminal cover (frame 1, 2 and 3)
1. DC terminal cover.
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2
1
WARNING
Figure 4-4 Opening of the DC terminal cover (frame 1, 2 and 3)
1. Undo the Torx slotted screw (T10 torx screwdriver).
2. The DC cover can then be hinged downwards or removed.
When replacing the terminal covers, the M3 screw should be tightened to a torque of 1 N m (8.9 lb in).
4.3.2 DC busbar cable connection
Cable connections to the DC terminals should be made with a suitably insulated M4 ring crimp (up to maximum 6 mm2 cable).
Figure 4-5 DC supply connections and cable routing
• Remove only one DC terminal cover breakout tab (1) when supplying a standalone drive.
DC cable grommets must be fitted when DC terminal cover breakout tabs are removed. Suitable grommets are available from the supplier
of the drive. Refer to section 2.8.1 Installation and system accessory kits available with Digitax HD M75X series on page 14.
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WARNING
NOTE
NOTE
4.4 External 24 Vdc supply
The drive will power down and reset if the external 24 Vdc is removed.
An external 24 Vdc supply is required to power all the low voltage requirements within the drive.
The cable length between the 24 Vdc power supply and the drive should not exceed 10 m.
The 0V connection of the external 24 Vdc power supply should be connected to the same ground connection as the drive. Where this is not possible
the 0V connection of the 24 Vdc power supply should be floating.
The working voltage range of the drive 24 V power circuit is as follow:
Table 4-4 Working voltage range of the 24 Vdc supply
All frame sizes
Nominal operating voltage 24.0 Vdc
Minimum continuous operating voltage 20.4 V
Maximum continuous operating voltage 28.8 V
Minimum start up voltage 20.4 V
Maximum fuse rating 30 A
Table 4-5 24 Vdc typical input current and power requirements
Model / Option / Feature Frame size
Digitax HD M75X drive module
1, 2 894 21.5
3 1039 25
Typical input current (mA)
@ 24 V
SI-option module Per module 450 11
High current brake output All 1200 28.8
KI-Compact display All 10 0.24
KI-Remote LCD keypad All 73 1.75
Typical input power
(W)
During start up of the external 24 Vdc supply, allow for an additional 1 A for 300 ms.
Figure 4-6 Location of external 24 Vdc supply terminals
The 24 Vdc supply connector has been designed to allow wiring from either the left or right hand side of the drive. The same plug should be used but
attention is required to the polarity of the wiring. If it is reversed, the drive will not power up but will not be damaged.
For stand alone drives connection to either terminal is permissible.
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WARNING
NOTE
NOTE
4.5 Low voltage operation
The drive is able to operate from a low voltage DC supply with a range from 24 Vdc 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 new low voltage mode of operation, the under voltage trip level is now user programmable. For application data, contact the
supplier of the drive.
The working voltage range of the low voltage DC power supply is as follows:
Minimum continuous operating voltage: 26 V
Minimum start up voltage: 32 V
Maximum over voltage trip threshold: 230 V drives: 415 V
400 V drives: 830 V
4.6 Ratings
Fuses
The AC supply to the drive must be installed with suitable protection against overload and short-circuits. The following section shows
recommended fuse ratings. Failure to observe this requirement will cause risk of fire.
Table 4-6 Fuse ratings and cable sizes for single axis
Cable size
(for single axis)
Model
No of input
phases
Typical input
current
(for single axis)
Fuse ratings
(for single axis)
AIEC gG
UL Class
CC, J or T*
Input Output
mm²AWGmm²AWG
01200022 1 3.7 8 15 0.75 14 0.75 24
01200040 1 6.9 12 15 1.5 14 0.75 22
01200065 1 11.4 16 15 2.5 12 0.75 20
02200090 1 17.7 25 25 4.0 10 0.75 16
02200120 1 23.0 32 30 6.0 10 0.75 16
03200160 1 31.5 32 40 6.0 8 1.5 14
01200022 3 5.8 8 15 0.75 14 0.75 20
01200040 3 7.9 12 15 1.5 14 0.75 18
01200065 3 10.5 16 15 2.5 14 0.75 16
02200090 3 16.7 25 25 4.0 10 1.0 14
02200120 3 20.3 32 30 6.0 10 1.5 12
03200160 3 27.9 32 40 6.0 8 2.5 12
01400015 3 3.1 6 15 0.75 14 0.75 20
01400030 3 4.8 8 15 0.75 14 0.75 20
01400042 3 5.3 8 15 0.75 14 0.75 18
02400060 3 10.1 16 25 2.5 14 0.75 16
02400080 3 12.1 16 25 2.5 12 0.75 14
02400105 3 14.9 20 25 4.0 12 1.5 14
03400135 3 20.8 32 30 6.0 10 2.5 12
03400160 3 22.0 32 30 6.0 10 2.5 12
* These are fast acting fuses.
For multi-axis fuse and cable data refer to Section 5 Multi axis system design.
PVC insulated cable should be used.
Cable sizes are from IEC60364-5-52:2001 table A.52.C with correction factor for 40 °C ambient of 0.87 (from table A52.14) for cable installation
method B2 (multicore cable in conduit).
Cable size may be reduced if a different installation method is used, or if the ambient temperature is lower.
The recommended cable sizes above are only a guide. The mounting and grouping of cables affects their current-carrying capacity, in some cases
smaller cables may be acceptable but in other cases a larger cable is required to avoid excessive temperature or voltage drop. Refer to local wiring
regulations for the correct size of cables.
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NOTE
WARNING
NOTE
Use 105 °C (221 °F) (UL 75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power
connections:
• AC supply (or external EMC filter) to drive.
• Drive to braking resistor.
Input cable sizes should generally be regarded as a minimum, since they have been selected for co-ordination with the recommended fuses.
The drive power terminals are designed for a maximum cable size of 10 mm
²
(8 AWG), (minimum 0.05 mm / 30 AWG). Where more than one cable
per terminal is used the combined diameters should not exceed the maximum. The terminals are suitable for both solid and stranded wires.
An MCB (miniature circuit breaker) may be used in place of fuses under the following conditions:
• The fault-clearing capacity must be sufficient for the installation
• The I
²
T rating of the MCB must be less than or equal to that of the fuse rating listed above.
A fuse or other protection must be included in all live connections to the AC supply.
For a parallel DC bus system the maximum AC input fusing is shown in Table 4-7.
Table 4-7 Maximum AC input fusing
Model
IEC class gG UL class J
mm
2
AWG
All 40 40 6 8
Refer to Chapter 5 Multi axis system design on page 84 for further information regarding DC bus paralleling.
4.7 Output circuit and motor protection
The output circuit has fast-acting electronic short-circuit protection which limits the fault current to typically no more than five times the rated output
current, and interrupts the current in approximately 20 µs. No additional short-circuit protection devices are required.
The drive provides overload protection for the motor and its cable. For this to be effective, Rated Current (05.007) must be set to suit the motor
Rated Current (05.007) must be set correctly to avoid a risk of fire in the event of motor overload.
There is also provision for the use of a motor thermistor to prevent over-heating of the motor, e.g. due to loss of cooling.
4.7.1 Motor cable types
Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 4-
8.
Cable sizes are given for guidance only and may be changed depending on the application and the method of installation of the cables.
The mounting and grouping of cables affect their current capacity, in some cases a larger cable is required to avoid excessive temperature or voltage
drop.
The recommended output cable sizes assume that the motor maximum current matches that of the drive. Where a motor of reduced rating is used the
cable rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against overload, the drive must be
programmed with the correct motor rated current (Pr 05.007).
• Cable lengths in excess of the specified values may be used only when special techniques are adopted; refer to the supplier of the drive.
Fuse rating Fuse rating Input cable size
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Normal capacitance
Shield or armour
separated from the cores
High capacitance
Shield or armour close
to the cores
Table 4-8 Motor cable size and maximum lengths
Model
01200022 1 0.75 24
01200040 1 0.75 22
01200065 1 0.75 20
02200090 1 0.75 16
02200120 1 0.75 16
03200160 1 1.5 14
01200022 3 0.75 20
01200040 3 0.75 18
01200065 3 0.75 16
02200090 3 1.0 14
02200120 3 1.5 12
03200160 3 2.5 12
01400015 3 0.75 20
01400030 3 0.75 20
01400042 3 0.75 18
02400060 3 0.75 16
02400080 3 0.75 14
02400105 3 1.5 14
03400135 3 2.5 12
03400160 3 2.5 12
Number of
input
phases
Output cable
mm²
AWG
All switching frequencies
50 m
50 m
4.7.2 High-capacitance / reduced diameter cables
The maximum cable length is reduced from that shown in Table 4-8 if high capacitance or reduced diameter motor cables are used.
Most cables have an insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended.
Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that
quoted in the tables, (Figure 4-7 shows how to identify the two types).
Figure 4-7 Cable construction influencing the capacitance
The maximum motor cable lengths specified in Table 4-8 are shielded and contain four cores. Typical capacitance for this type of cable is 130 pF/m
(i.e. from one core to all others and the shield connected together).
4.7.3 Motor winding voltage
The PWM output voltage can adversely affect the inter-turn insulation in the motor. This is because of the high rate of change of voltage, in
conjunction with the impedance of the motor cable and the distributed nature of the motor winding.
For normal operation with AC supplies up to 500 Vac and a standard motor with a good quality insulation system, there is no need for any special
precautions. In case of doubt the motor supplier should be consulted. Special precautions are recommended under the following conditions, but only
if the motor cable length exceeds 10 m:
• AC supply voltage exceeds 500 V
• DC supply voltage exceeds 670 V, i.e regenerative / AFE supply.
• Operation of 400 V drive with continuous or very frequent sustained braking
• Multiple motors connected to a single drive
It is recommended that an inverter-rated motor be used taking into account the voltage rating of the inverter. This has a reinforced insulation system
intended by the manufacturer for repetitive fast-rising pulsed voltage operation.
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.
56 Digitax HD M75X Series Installation and Technical Guide
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WARNING
NOTE
WARNING
NOTE
4.7.4 / motor operation
The voltage rating for and connections of the motor should always be checked before attempting to run the motor.
The default setting of the motor rated voltage parameter is the same as the drive rated voltage, i.e.
400 V drive 400 V rated voltage
230 V drive 230 V rated voltage
A typical 3 phase motor would be connected in
690 V
400 V. Incorrect connection of the windings will cause severe under or over fluxing of the motor, leading to a very poor output torque or
for 400 V operation or for 230 V operation, however, variations on this are common e.g.
motor saturation and overheating respectively.
4.7.5 Output contactor
If the cable between the drive and the motor is to be interrupted by a contactor or circuit breaker, ensure that the drive is disabled before
the contactor or circuit breaker is opened or closed. Severe arcing may occur if this circuit is interrupted with the motor running at high
current and low speed.
A contactor is sometimes required to be installed between the drive and motor for safety purposes.
The recommended motor contactor is the AC3 type.
Switching of an output contactor should only occur when the output of the drive is disabled.
Opening or closing of the contactor with the drive enabled will lead to:
1. OI ac trips (which cannot be reset for 10 seconds)
2. High levels of radio frequency noise emission
3. Increased contactor wear and tear
The STO1, STO2 terminal when opened, provides a Safe Torque Off function. This can in many cases replace output contactors.
For further information see the relevant Digitax HD M75X Control User Guide.
4.8 Braking
Braking occurs when the drive is decelerating the motor, or is preventing the motor from gaining speed due to mechanical influences. During braking,
energy is returned to the drive from the motor.
When motor braking is applied by the drive, the maximum regenerated power that the drive can absorb is equal to the power dissipation (losses) of
the drive.
When the regenerated power is likely to exceed these losses, the DC bus voltage of the drive increases. Under default conditions, the drive brakes
the motor under PI control, which extends the deceleration time as necessary in order to prevent the DC bus voltage from rising above a user defined
set-point.
If the drive is expected to rapidly decelerate a load, or to hold back an overhauling load, a braking resistor must be installed.
Table 4-9 shows the default DC voltage level at which the drive turns on the braking transistor. However the braking resistor turn on and the turn off
voltages are programmable with Braking IGBT Lower Threshold (06.073) and Braking IGBT Upper Threshold (06.074).
Table 4-9 Default braking transistor turn on voltage
Drive voltage rating DC bus voltage level
200 V 390 V
400 V 780 V
When a braking resistor is used, Pr 02.004 should be set to Fast ramp mode.
4.8.1 Compact braking resistor
A resistor has been designed to be mounted on the side of the drive.
See section 3.13.1 Compact braking resistor on page 32 for mounting details. The design of the resistor is such that no thermal protection circuit is
required, as the device will fail safety under fault conditions. The in built software overload protection is set-up at default for the designated compact
resistor. The compact resistor is not supplied with the drive and can be purchased separately, refer to section 2.8 Installation and system accessories
on page 14.
Side by side mounting is still permissible with compact braking resistor fitted.
Table 4-10 provides the compact braking resistor data.
High temperatures
Braking resistors can reach high temperatures. Locate braking resistors so that damage cannot result. Use cable having insulation capable
of withstanding high temperatures.
The compact resistor is suitable for applications with a low level of regenerative energy only.
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CAUTION
Parameter
All frames
200 V drive 400 V drive
Braking resistor rated power Pr 10.030 50 W
Braking resistor thermal time constant Pr 10.031 2 s
Braking resistor resistance Pr 10.061 70
WARNING
Braking resistor overload protection parameter settings.
Failure to observe the following information may damage the resistor.
The drive software contains an overload protection function for a braking resistor, this function is enabled at default to protect the compact
resistor.
Below are the parameter settings.
For more information on the braking resistor software overload protection, see Pr 10.030, Pr 10.031 and Pr 10.061 full descriptions in the
relevant Control User Guide.
Table 4-10 Compact braking resistor data
Parameter All frames
Part number 3470-0152
DC resistance at 25 °C 70
Peak instantaneous power over 1 ms at nominal resistance
Average power over 60 s 50 W
200 V 400 V
2.2 kW 8.7 kW
4.8.2 External braking resistor
Thermal protection
When an external braking resistor is used, it is essential that a thermal protection device is incorporated in the braking resistor circuit.
When a braking resistor is to be mounted outside the enclosure, ensure that it is mounted in a ventilated metal housing that will perform the following
functions:
• Prevent inadvertent contact with the resistor
• Allow adequate ventilation for the resistor
When compliance with EMC emission standards is required, external connection requires the cable to be armored or shielded, since it is not fully
contained in a metal enclosure. See section 4.10 EMC (Electromagnetic compatibility) on page 61 for further details.
Internal connection does not require the cable to be armored or shielded.
Table 4-11 Minimum resistance values and peak power rating for the braking resistor at 40 °C (104 °F)
Minimum resistance*
Model
200 V
01200022 25 6 2 2
01200040 25 6 2 2
01200065 25 6 2 2
02200090 13 11.1 3.7 2
02200120 13 11.1 3.7 2
03200160 10 15 5 2
400 V
01400015 106 5.7 1.9 2
01400030 106 5.7 1.9 2
01400042 106 5.7 1.9 2
02400060 36 16.8 5.6 2
02400080 36 16.8 5.6 2
02400105 36 16.8 5.6 2
03400135 26 22.8 7.6 2
03400160 26 22.8 7.6 2
(Pr 10.061)
Ω kW kW s
Peak power rating
Continuous power rating
(Maximum Pr 10.030 setting)
Maximum braking resistor
thermal time constant
(Pr 10.031)
* Resistor tolerance: ±10 %. The minimum resistance specified are for stand-alone drive systems only. If the drive is to be used as part of a common
DC bus system different values may be required. See Braking resistor software overload protection on page 60.
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Optional
EMC
filter
Stop
Start /
Reset
Thermal
protection
device
Braking resistor
Drive
Main contactor
power supply
+DC
BR
For high-inertia loads or under continuous braking, the continuous power dissipated in the braking resistor may be as high as the power rating of the
drive. The total energy dissipated in the braking resistor is dependent on the amount of energy to be extracted from the load.
The instantaneous power rating refers to the short-term maximum power dissipated during the on intervals of the pulse width modulated braking
control cycle. The braking resistor must be able to withstand this dissipation for short intervals (milliseconds). Higher resistance values require
proportionately lower instantaneous power ratings.
In most applications, braking occurs only occasionally. This allows the continuous power rating of the braking resistor to be much lower than the
power rating of the drive. It is therefore essential that the instantaneous power rating and energy rating of the braking resistor are sufficient for the
most extreme braking duty that is likely to be encountered. Optimization of the braking resistor requires careful consideration of the braking duty.
Select a value of resistance for the braking resistor that is not less than the specified minimum resistance. Larger resistance values may give a cost
saving. Braking capability will then be reduced, which could cause the drive to trip during braking if the value chosen is too large.
The following external brake resistors are available from the supplier of the drive for all frame sizes.
Table 4-12 External brake resistors (40 °C ambient) for all frame sizes
Part
number
Part
description
Ohmic
value
Pr 10.061
Continuous
power
rating
Pr 10.030
Max instant
power rating
ton = 1 ms
Pulse power
1/120 s
(ED 0.8 %)
Pulse power
5/120 s
(ED 4.2 %)
Pulse power
10/120 s
(ED 8.3 %)
Pulse power
40/120 s
(ED 33 %)
Time
constant
Pr 10.031
DBR.
1220-2201
100 W,
20R, 130 x
20
Ω 100 W 2.0 MW 2300 W 1000 W 650 W 250 W 2
68, TS
DBR.
1220-2401
100 W,
40R, 130 x
40 Ω 100 W 1.6 MW 1900 W 900 W 610 W 240 W 2
68, TS
DBR.
1220-2801
100 W,
80R, 130 x
80 Ω 100 W 1.25 MW 1500 W 775 W 570 W 230 W 2
68, TS
The thermal switch should be integrated in the control circuit by the user.
Pr 10.030, Pr 10.031 and Pr 10.061 should be set as per information provided in Table 4-11. Refer to description of Pr 10.030, Pr 10.031 and
Pr 10.061 in section 4.8.3 Braking resistor software overload protection on page 60 for more information.
Thermal protection circuit for the braking resistor
The thermal protection circuit must disconnect the AC supply from the drive if the resistor becomes overloaded due to a fault. Figure 4-8 shows a
typical circuit arrangement.
Figure 4-8 Typical protection circuit for a braking resistor
See Figure 4-1 on page 48 for the location of the +DC and braking resistor connections.
Digitax HD M75X Series Installation and Technical Guide 59
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WARNING
4.8.3 Braking resistor software overload protection
The drive software contains an overload protection function for a braking resistor. In order to enable and set-up this function, it is necessary to enter
three values into the drive:
• Braking Resistor Rated Power (10.030)
• Braking Resistor Thermal Time Constant (10.031)
• Braking Resistor Resistance (10.061)
This data should be obtained from the manufacturer of the braking resistor.
The brake resistor thermal time constant (Pr 10.031) is used to limit the energy dissipated in a resistor when braking overload energy. For the Digitax
HD M75X drives, the brake resistor thermal time constant should be set to a maximum of 2 seconds. This will protect both the drive and the brake
resistor from excessive temperatures. Full overload and continuous braking levels are achievable with this setting.
Pr 10.039 gives an indication of braking resistor temperature based on a simple thermal model. Zero indicates the resistor is close to ambient and
100 % is the maximum temperature the resistor can withstand. A ‘Brake Resistor’ alarm is given if this parameter is above 75 % and the braking IGBT
is active. A Brake R Too Hot trip will occur if Pr 10.039 reaches 100 %, when Pr 10.037 is set to 0 (default value) or 1.
If Pr 10.037 is equal to 2 or 3, a Brake R Too Hot trip will not occur when Pr 10.039 reaches 100 %, but instead the braking IGBT will be disabled until
Pr 10.039 falls below 95 %. This option is intended for applications with parallel connected DC buses where there are several braking resistors, each
of which cannot withstand full DC bus voltage continuously. With this type of application it is unlikely the braking energy will be shared equally
between the resistors because of voltage measurement tolerances within the individual drives. Therefore with Pr 10.037 set to 2 or 3, then as soon as
a resistor has reached its maximum temperature the drive will disable the braking IGBT, and another resistor on another drive will take up the braking
energy. Once Pr 10.039 has fallen below 95 % the drive will allow the braking IGBT to operate again.
See the Parameter Reference Guide for more information on Pr 10.030, Pr 10.031, Pr 10.037 and Pr 10.039.
This software overload protection should be used in addition to an external overload protection device.
4.9 Ground leakage (PE current)
The ground leakage current depends upon whether the internal EMC filter is installed or not. The drive is supplied with the filter installed. Instructions
for disconnecting the internal filter are given in section 4.10.3 Internal EMC filter on page 65.
Table 4-13 Ground leakage with and without Internal EMC filter installed
With internal EMC
Drive
M75X-0120022 7.7 2.8
M75X-0120040 7.7 2.8
M75X-0120065 7.7 2.8
M75X-0220090 10.9 8.9
M75X-0220120 10.9 8.9
M75X-0320160 8.1 1.6
M75X-0140015 13.9 4.4
M75X-0140035 13.9 4.4
M75X-0140042 13.9 4.4
M75X-0240060 16.5 6.8
M75X-0240080 16.5 6.8
M75X-0240105 16.5 6.8
M75X-0340135 16.3 3.8
M75X-0340160 16.3 3.8
filter connected
mA mA
*
With internal EMC
filter disconnected
*
* These are RMS values within a 1.5 kHz bandwidth measured with a configuration of 2 m SY cable connected to a common 4 pole motor cable at a
switching frequency of 8 kHz having the motor frame only connected to the ground potential through the motor cable. Refer to the Digitax HD M75X
series EMC data sheet, available from the supplier of the drive.
When the internal filter is installed the leakage current is above 3.5 mA. In this case a permanent fixed, low impedance, low inductance
ground connection between the drive’s metal frame and PE must be provided, or other suitable measures taken to prevent a safety hazard
occurring if the connection is lost.
4.9.1 Use of residual current device (RCD)
There are three common types of ELCB / RCD:
1. AC - detects AC fault currents
2. A - detects AC and pulsating DC fault currents (provided the DC current reaches zero at least once every half cycle)
3. B - detects AC, pulsating DC and smooth DC fault currents
• Type AC should never be used with drives
• Type A can only be used with single phase drives
60 Digitax HD M75X Series Installation and Technical Guide
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WARNING
• Type B must be used with three phase drives
Only type B ELCB / RCD are suitable for use with 3 phase inverter drives.
If an external EMC filter is used, a delay of at least 50 ms should be incorporated to ensure spurious trips are not seen. The leakage current is likely
to exceed the trip level if all of the phases are not energized simultaneously.
Ground leakage current will increase when operating on a single phase supply, it may be necessary therefore to disconnect the internal EMC filter to
ensure spurious RCD trips are not seen. Instructions for disconnecting the Internal EMC filter are given in section 4.10.3 Internal EMC filter on
page 65.
4.10 EMC (Electromagnetic compatibility)
The requirements for EMC are divided into three levels in the following three sections:
• Section 4.10.4 General requirements for EMC Ground (earth) connections, this is for all applications, to ensure reliable operation of the drive and
minimise the risk of disturbing nearby equipment. The immunity standards specified in section 4.10 EMC (Electromagnetic compatibility) on
page 61 will be met, but no specific emission standards are applied.
• Section 4.10.6 Compliance with EN 61800-3:2004+A1:2012 (standard for Power Drive Systems), Requirements for meeting the EMC standard
for power drive systems, IEC 61800-3 (EN 61800-3:2004+A1:2012).
• Section 4.10.7 Compliance with generic emission standards, Requirements for meeting the generic emission standards for the industrial
environment, IEC 61000-6-4, EN 61000-6-4:2007+A1:2011.
The recommendations of section 4.10.4 will usually be sufficient to avoid causing disturbance to adjacent equipment of industrial quality. If particularly
sensitive equipment is to be used nearby, or in a non-industrial environment, then the recommendations of section 4.10.6 or section 4.10.7 should be
followed to give reduced radio-frequency emission.
In order to ensure the installation meets the various emission standards described in:
• The EMC data sheet available from the supplier of the drive.
• The Declaration of Conformity at the front of this manual.
• Chapter 6 Technical data on page 98.
The correct external EMC filter must be used and all of the guidelines in section 4.10.4 General requirements for EMC Ground (earth) connections on
page 67 and section 4.10.7 Compliance with generic emission standards on page 69 must be followed.
4.10.1 Optional external EMC filters
The external EMC filter details for the Digitax HD M75X drive series are provided in the Table 4-15.
Table 4-14 Drive and EMC filter cross reference
Model Number of phases Part number
200 V
01200022 1
4200-350301200040 1
01200065 1
02200090 1
02200120 1
03200160 1 4200-6034
01200022 3 4200-8744
01200040 3 4200-6002
01200065 3 4200-6001
02200090 3 4200-5833
02200120 3 4200-5833
03200160 3 4200-5833
400 V
01400015 to 01400042 3 4200-8744
02400060 to 02400105 3 4200-1644
03400135 to 03400160 3 4200-5833
4200-5033
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WARNING
NOTE
2
1
3
Table 4-15 External EMC filter ratings
Part number
Number of
phases
Maximum continuous
current
@40C
(104F)
@50C
(122F)
Maximum voltage
rating
IEC UL
Power
losses at
rated
current
IP
rating
Weight
Operational
leakage current
AAVVW kglbmA mA
4200-3503 1 30 27.3 250 250 6.1 20 0.7 1.5 5.4 10.8
4200-5033 1 55 50.1 250 250 9.9 20 1.2 2.6 11 22
4200-6034 1 65.7 60 250 250 5.5 20 1.8 4.0 3.4 6.8
4200-8744 3 7.7 7 480 480 3.8 20 0.5 1.1 33 178.2
4200-6002 3 11 10 480 480 10 20 1.2 2.64 16 90
4200-6001 3 17 15.5 250 250 13 20 1.2 2.64 8 50
4200-1644 3 17.5 16 480 480 6.1 20 0.8 1.76 33 178.2
4200-5833 3 32.9 30 480 480 11.8 20 1.2 2.64 33 178.2
4200-3233 3 46 42 480 480 15.7 20 1.4 3.1 33 178.2
4200-5534 3 60.2 55 480 480 25.9 20 2.0 4.4 33 178.2
4200-7534 3 82.2 75 480 480 32.2 20 2.7 6.0 33 178.2
4200-0035 3 109.5 100 480 480 34.5 20 4.3 9.5 33 178.2
For external EMC filter dimensions and terminal data refer to section 3.14 External EMC filter on page 36.
High ground leakage current
When an EMC filter is used, a permanent fixed ground connection must be provided which does not pass through a connector or flexible
power cord. This includes the internal EMC filter.
Worst
case
leakage
current
The installer of the drive is responsible for ensuring compliance with the EMC regulations that apply in the country in which the drive is to be used.
4.10.2 Grounding hardware
The drive is supplied with a cable screen bracket to facilitate EMC compliance. The bracket provides a convenient method for direct grounding of
cable shields without the use of “pig-tails”. Cable shields can be bared and clamped to the cable screen bracket using metal clips or cable ties. Note
that, where applicable, the shield must in all cases be continued through the cable screen bracket to the intended terminal on the drive, in accordance
with the connection details for the specific signal.
• See Figure 4-10 for details on installing the cable screen bracket.
Figure 4-9 Attaching the cable screen bracket to the motor, feedback and control wiring (frame sizes 1 and 2)
• Expose outer cable shields (1).
• The cable screen bracket (2) must be tie wrapped to the motor, feedback and control wiring (3).
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3
1
2
1
2
3
Figure 4-10 Installation of cable screen bracket (frame sizes 1 and 2)
• Slide the tab on the cable screen bracket (1) into the slot formed in the metal side plate (2) and secure to the drive with M4 screw (3). Torque
2 N m (17.7 lb in).
Figure 4-11 Attaching the cable screen bracket to the motor, feedback and control wiring (frame size 3)
• Expose outer cable shields (1).
• The cable screen bracket (2) must be tie wrapped to the motor, feedback and control wiring (3).
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2
1
3
Figure 4-12 Installation of cable screen bracket (frame size 3)
• Secure the cable screen bracket (1) to the tab on the metal side plate (2) with M4 screw (3). Torque 2 N m (17.7 lb in).
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WARNING
1
4.10.3 Internal EMC filter
It is recommended that the internal EMC filter be kept in place unless there is a specific reason for disconnecting it.
The internal EMC filter reduces radio-frequency emissions into the line power supply. Where the motor cable is short, it permits the requirements of
EN 61800-3:2004+A1:2012 to be met for the second environment.
For longer motor cables, the filter continues to provide a useful reduction in emission level, and when used with any length of shielded cable up to the
limit of the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the
ground leakage current is unacceptable or the above conditions are true.
The supply must be disconnected before disconnecting the internal EMC filter.
Figure 4-13 Disconnection of the internal EMC filter on Frame 1
• To electrically disconnect the internal EMC filter, remove the screw (1) as shown above.
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1
1
Figure 4-14 Disconnection of the internal EMC filter on Frame 2
• To electrically disconnect the internal EMC filter, remove the screw (1) as shown above.
Figure 4-15 Disconnection of the internal EMC filter on Frame 3
• To electrically disconnect the internal EMC filter, remove the screw (1) as shown above.
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External
controller
0V
If the control circuit 0V
is to be grounded, this
should be done at the
system controller only to
avoid injecting noise
currents into the 0V circuit
Metal backplate
Grounding bar
PE
~
PE
If ground connections are
made using a separate
cable, they should run
parallel to the appropriate
power cable to minimise
emissions
Use four core cable to
connect the motor to the drive.
The ground conductor in the
motor cable must be connected
directly to the earth terminal of
the drive and motor.
It must not be connected directly
to the power earth busbar.
The incoming supply ground
should be connected to a
single power ground bus bar
or low impedance earth
terminal inside the cubicle.
This should be used as a
common 'clean' ground for all
components inside the cubicle.
3 phase AC supply
Optional EMC
filter
Metal backplate
safety bonded to
power ground busbar
4.10.4 General requirements for EMC Ground (earth) connections
The grounding arrangements should be in accordance with Figure 4-16, which shows a single drive on a back-plate with or without an additional
enclosure.
Figure 4-16 shows how to configure and minimise EMC when using unshielded motor cable. However shielded cable is a better option, in which case
it should be installed as shown in section 4.10.7 Compliance with generic emission standards on page 69.
Figure 4-16 General EMC enclosure layout showing ground connections
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Optional braking resistor and overload
Do not place sensitive
(unscreened) signal circuits
in a zone extending
300 mm (12”) all around the
Drive, motor cable, input
cable from EMC filter and
unshielded braking resistor
cable (if used)
300mm
(12in)
NOTE
4.10.5 Cable layout
Figure 4-17 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals /
equipment.
Figure 4-17 Drive cable clearances
Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable
capacitance. The shield of these signal cables must be connected to ground close to the motor cable, to avoid this noise current spreading through
the control system.
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CAUTION
CAUTION
³100 mm
(4 in)
Do not modify
the filter wires
4.10.6 Compliance with EN 61800-3:2004+A1:2012 (standard for Power Drive Systems)
Meeting the requirements of this standard depends on the environment that the drive is intended to operate in, as follows:
Operation in the first environment
Observe the guidelines given in Section 4.10.7 Compliance with generic emission standards. An external EMC filter will always be required.
This is a product of the restricted distribution class according to IEC 61800-3.
In a residential environment this product may cause radio interference in which case the user may be required to take adequate measures.
Operation in the second environment
In all cases a shielded motor cable must be used, and an EMC filter is required for all drives with a rated input current of less than 100 A.
The drive contains an in-built filter for basic emission control. In some cases feeding the motor cables (U, V and W) once through a ferrite ring can
maintain compliance for longer cable lengths.
Depending on the level of compliance required, motor cable length and inverter switching frequency, an external EMC filter may or may not be
needed; refer to section 6.1.26 Electromagnetic compatibility (EMC) on page 110 for more information.
For longer motor cables, an external filter is required. Where a filter is required, follow the guidelines in section 4.10.7 Compliance with generic
emission standards on page 69.
Where a filter is not required, follow the guidelines given in section 4.10.4 General requirements for EMC Ground (earth) connections on page 67.
The second environment typically includes an industrial low-voltage power supply network which does not supply buildings used for
residential purposes. Operating the drive in this environment without an external EMC filter may cause interference to nearby electronic
equipment whose sensitivity has not been appreciated. The user must take remedial measures if this situation arises. If the consequences
of unexpected disturbances are severe, it is recommended that the guidelines in Section 4.10.7 Compliance with generic emission
standards be adhered to.
Refer to section 4.10 EMC (Electromagnetic compatibility) on page 61 for further information on compliance with EMC standards and definitions of
environments.
Detailed instructions and EMC information are given in the Digitax HD M75X EMC Data Sheet which is available from the supplier of the drive.
4.10.7 Compliance with generic emission standards
Use the recommended filter and shielded motor cable. Observe the layout rules given in Figure 4-18 and Figure 4-19. Ensure the AC supply and
ground cables are at least 100 mm from the power module and motor cable.
Figure 4-18 Supply and ground cable clearance
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Sensitive
signal
cable
³300 mm
(12 in)
1
2
Figure 4-19 Sensitive signal circuit clearance
Avoid placing sensitive signal circuits in a zone 300 mm (12 in) in the area immediately surrounding the power module. Ensure good EMC grounding.
Figure 4-20 Grounding the drive, motor cable shield and filter
1. Ensure direct metal contact at drive mounting points (any paint must be removed).
2. Motor cable shield (unbroken) electrically connected to and held in place by cable screen bracket.
Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50 mm
(2 in) long.
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BR 2BR 1
Optional external
braking resistor
Enclosure
Optional external
braking resistor
Enclosure
OR
BR 1 BR 2
A complete 360 termination of the shield to the terminal housing of the motor is beneficial.
From an EMC consideration it is irrelevant whether the motor cable contains an internal (safety) ground core, or if there is a separate external ground
conductor, or where grounding is through the shield alone. An internal ground core will carry a high noise current and therefore it must be terminated
as close as possible to the shield termination.
Figure 4-21 Grounding the motor cable shield
Unshielded wiring to the optional braking resistor(s) may be used provided the wiring runs internally to the enclosure. Ensure a minimum spacing of
300 mm (12 in) from the signal wiring and the AC supply wiring to the external EMC filter. If this condition cannot be met then the wiring must be
shielded.
Figure 4-22 Shielding requirements of optional external braking resistor
If the control wiring is to leave the enclosure, it must be shielded and the shield(s) clamped to the drive using the cable screen bracket as shown in
Figure 4-20. Remove the outer insulating cover of the cable to ensure the shield(s) make direct contact with the bracket, but keep the shield(s) intact
until as close as possible to the terminals. Alternatively, wiring may be passed through a ferrite ring, part number 3225-1004.
4.10.8 Variations in the EMC wiring
Interruptions to the motor cable
The motor cable should ideally be a single length of shielded or armored cable having no interruptions. In some situations it may be necessary to
interrupt the cable, as in the following examples:
• Connecting the motor cable to a terminal block in the drive enclosure
• Installing a motor isolator / disconnect switch for safety when work is done on the motor
In these cases the following guidelines should be followed.
Terminal block in the enclosure
The motor cable shields should be bonded to the back-plate using un-insulated 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.
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From the Drive
To the motor
Back-plate
Enclosure
Isolator
Coupling bar
From the
Drive
To the
motor
(If required)
Signal from plant Signal to drive
0V 0V
30V zener diode
e.g. 2xBZW50-15
Figure 4-23 Connecting the motor cable to a terminal block in the enclosure
Using a motor isolator / disconnect-switch
The motor cable shields should be connected by a very short conductor having a low inductance. The use of a flat metal coupling-bar is
recommended; conventional wire is not suitable.
The shields should be bonded directly to the coupling-bar using un-insulated 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 4-24 Connecting the motor cable to an isolator / disconnect switch
4.10.9 Surge immunity of control circuits - long cables and connections outside a building
The input/output ports for the control circuits are designed for general use within machines and small systems without any special precautions.
These circuits do not meet the requirements of EN 61000-6-2:2005 (1 kV surge) without external protection.
In applications where they may be exposed to high-energy voltage surges, some special measures may be required to prevent malfunction or
damage. Surges may be caused by lightning or severe power faults in association with grounding arrangements which permit high transient voltages
between nominally grounded points. This is a particular risk where the circuits extend outside the protection of a building.
As a general rule, if the circuits are to pass outside the building where the drive is located, or if cable runs within a building exceed 30 m, some
additional precautions are advisable. One of the following techniques should be used:
1. Shielded cable with additional power ground bonding. The cable shield may be connected to ground at both ends, but in addition the ground
conductors at both ends of the cable must be bonded together by a power ground cable (equipotential bonding cable) with cross-sectional area of at
least 10 mm
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.
2. Additional over-voltage suppression - for the analog and digital inputs and outputs, a zener diode network or a commercially available surge
suppressor may be connected in parallel with the input circuit as shown in Figure 4-25 and Figure 4-26.
If a digital port experiences a severe surge its protective trip may operate (I/O Overload trip). For continued operation after such an event, the trip can
be reset automatically by setting Pr 10.034 to 5.
Figure 4-25 Surge suppression for digital and unipolar inputs and outputs
2
, 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
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Signal from plant Signal to drive
0V 0V
2 x 15V zener diode
e.g. 2xBZW50-15
NOTE
0 V common
1
2
3
4
5
6
7
Digital Output 1
Run forward
Run reverse
Safe Torque Off
Input 1*
0 V common
+24 V / Digital Output 3
11
12
13
Safe Torque Off
Input 2*
Digital Output 2
0 V common
0 V common
0 V common
0V common
9
10
8
14
15
16
0 V common
1
Figure 4-26 Surge suppression for analog and bipolar inputs and outputs
Surge suppression devices are available as rail-mounting modules, e.g. from Phoenix Contact:
Unipolar TT-UKK5-D/24 DC
Bipolar TT-UKK5-D/24 AC
These devices are not suitable for encoder signals or fast digital data networks because the capacitance of the diodes adversely affects the signal.
Most encoders have galvanic isolation of the signal circuit from the motor frame, in which case no precautions are required. For data networks, follow
the specific recommendations for the particular network.
4.11 Control terminals
The control circuits are isolated from the power circuits in the drive by reinforced insulation.
Figure 4-27 Default control terminal functions
1. Polarized signal connections.
* The Safe Torque Off / Drive enable terminal is a positive logic input only
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4.11.1 Digitax HD M75X Control terminal specification
1 0V common
3 0V common
4 0V common
5 0V common
7 0V common
8 0V common
15 0V common
Common connection for all external
Function
2 Safe Torque Off function input 1 (drive enable)
6 Safe Torque Off function input 2 (drive enable)
Type Positive logic only digital input
Voltage range 0V to +24 V
Absolute maximum applied voltage 30 V
Logic Threshold 10 V ± 5 V (IEC 61131-2 type 1)
Low state maximum voltage for
disable to SIL3 and PL e
Impedance
Low state maximum current for
disable to SIL3 and PL e
Response time
The Safe Torque Off function may be used in a safety-related application in
preventing the drive from generating torque in the motor to a high level of
integrity. The system designer is responsible for ensuring that the complete
system is safe and designed correctly according to the relevant safety standards.
If the Safe Torque Off function is not required, these terminals are used for
enabling the drive.
Refer to section 4.14 Safe Torque Off (STO) on page 82 for further
information.
devices. Internally connected to
ground.
5 V
>2 mA @15 V (IEC 61131-2, type 1
<0.5 mA (IEC 61131-2 type 1)
Nominal: 8 ms
Maximum: 20 ms
Analog input
9 Inverting input
10 Non-inverting input
Default function Frequency/speed reference
Type of input Bipolar differential analog voltage
Mode controlled by: Pr 07.007
Operating in Voltage mode
Full scale voltage range ±10 V ±2 %
Maximum offset ±10 mV
Absolute maximum
voltage range
Absolute maximum differential
input voltage
Working common mode voltage
range
Input resistance 100 k
Monotonic Yes (including 0V)
Dead band None (including 0V)
Jumps None (including 0V)
Maximum offset 20 mV
Maximum non linearity 0.3% of input
Maximum gain asymmetry 0.5 %
Input filter bandwidth single pole ~3 kHz
Resolution 12 bits (11 bits plus sign)
Sample / update period
±36 V relative to 0V
±36 V
±13 V relative to 0V
250 µs with destinations Pr 01.036,
Pr 01.037, Pr 03.022 or Pr 04.008 in RFC-A
and RFC-S modes. 4 ms for open loop
mode and all other destinations in RFC-A or
RFC-S modes.
11 Digital Input 4
Digital Input 5
13
Terminal 11 default function
Terminal 13 default function
Type Negative or positive logic digital inputs
Logic mode controlled by... Pr 08.029
Voltage range 0V to +24 V
Absolute maximum applied
voltage range
Impedance >2 mA @15 V (IEC 61131-2, type 1)
Input thresholds 10 V ±0.8 V (IEC 61131-2, type 1)
Sample / Update period
RUN FORWARD input
RUN REVERSE input
-3 V to +30 V
250 µs when configured as an input with
destinations Pr 06.035 or Pr 06.036. 600 µs
when configured as an input with destination
Pr 06.029. 2 ms in all other cases.
+24 V user output / Digital Output 3 (selectable)
12
Terminal 12 default function +24 V user output
Can be switched on or off to act as a third
Programmability
Nominal output current 100 mA
Maximum output current
Protection Current limit and trip
Sample / update period
digital output (positive logic only) by setting
the source Pr 08.028 and source invert
Pr 08.018
100 mA
200 mA (total including DO1)
2 ms when configured as an output (output
will only change at the update rate of the
source parameter if slower)
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5
10
15
1
6
11
Drive encoder connector
Female 15-way D-type
14 Digital Output 1
Terminal 14 default function AT ZERO SPEED output
Type Positive logic voltage source outputs
Operating as an output
Nominal maximum output current 100 mA
Maximum output current
Voltage range 0V to +24 V
Sample / Update period
200 mA (combined with +24 V user output/
DO3)
2 ms (output will only change at the
update rate of the source parameter
16 Digital Output 2
Terminal 16 default function High current motor brake output
Type Positive logic voltage source outputs
Operating as an output
Nominal output current 1 A (1.3 A max)
Voltage range 0V to +24 V
Sample / Update period
2 ms (output will only change at the
update rate of the source parameter
4.12 Position feedback connections
The following functions are provided via the 15-way high density D-type
connector on the drive:
• Two position feedback interfaces (P1 and P2).
• One encoder simulation output.
• Two freeze trigger inputs (marker inputs).
• One thermistor input.
The P1 position interface is always available but the availability of the P2
position interface and the encoder simulation output depends on the
position feedback device used on the P1 position interface, as shown in
Table 4-18.
4.12.1 Location of position feedback connector
Figure 4-28 Location of position feedback connector
4.12.2 Compatible position feedback devices
Table 4-16 Supported feedback devices on the P1 position interface
Encoder type Pr 03.038 setting
Quadrature incremental encoders with or without
marker pulse
Quadrature incremental encoders with UVW
commutation signals for absolute position for
permanent magnet motors with or without marker
pulse
Forward / reverse incremental encoders with or
without marker pulse
Forward / reverse incremental encoders with UVW
commutation signals for absolute position for
permanent magnet motors with or without marker
pulse
Frequency and direction incremental encoders
with or without marker pulse
Frequency and direction incremental encoders
with UVW commutation signals for absolute
position for permanent magnet motors with or
without marker pulse
Sincos incremental encoders SC (6)
Sincos incremental with commutation signals SC Servo (12)
Heidenhain sincos encoders with EnDat comms
for absolute position
Stegmann sincos encoders with Hiperface comms
for absolute position
Sincos encoders with SSI comms for absolute
position
Sincos incremental with absolute position from
single sin and cosine signals
SSI encoders (Gray code or binary) SSI (10)
EnDat communication only encoders EnDat (8)
Resolver Resolver (14)
UVW commutation only encoders* Commutation only
BiSS communication only encoders BiSS (13)
Sincos encoders with BiSS communications SC BiSS (17)
* This feedback device provides very low resolution feedback and should
not be used for applications requiring a high level of performance
Table 4-17 Supported feedback devices on the P2 position
interface
Encoder type
Quadrature incremental encoders with or without
marker pulse
Frequency and direction incremental encoders with or
without marker pulse
Forward / reverse incremental encoders with or
without marker pulse
EnDat communication only encoders EnDat (4)
SSI encoders (Gray code or binary) SSI (5)
BiSS communication only encoders BiSS (6)
Table 4-18 shows the possible combinations of position feedback device
types connected to the P1 and P2 position interfaces and the availability
of the encoder simulation output.
AB (0)
AB Servo (3)
FR (2)
FR Servo (5)
FD (1)
FD Servo (4)
SC EnDat (9)
SC Hiperface (7)
SC SSI (11)
SC SC (15)
(16)
Pr 03.138
setting
AB (1)
FD (2)
FR (3)
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NOTE
Table 4-18 Availability of the P2 position feedback interface and the encoder simulation output
Functions
P1 Position feedback interface P2 Position feedback interface Encoder Simulation Output
AB Servo
FD Servo
FR Servo
SC Servo
None None
SC SC
Commutation only
AB
FD
FR
AB, FD, FR
EnDat, SSI, BiSS
None
SC
Resolver
None Full
SC Hiperface
SC EnDat
SC SSI
SC BiSS
EnDat
SSI
BiSS
AB, FD, FR
(No Z marker pulse input)
None
EnDat, SSI (with freeze input), BiSS
None No Z marker pulse output
AB, FD, FR
EnDat, SSI (with freeze input), BiSS
None
None Full
EnDat, SSI, BiSS
No Z marker pulse output
The priority of the position feedback interfaces and the encoder simulation output on the 15-way D-type is assigned in the following order from the
highest priority to the lowest.
• P1 position interface (highest)
• Encoder simulation output
• P2 position interface (lowest)
For example, if an AB Servo type position feedback device is selected for use on the P1 position interface, then both the encoder simulation output
and the P2 position interface will not be available as this device uses all connections of the 15-way D-type connector. Also, if an AB type position
feedback device is selected for use on the P1 position interface and Pr 03.085 is set to a valid source for the encoder simulation output, then the P2
position interface will not be available.
Depending on the device type used on the P1 position interface, the encoder simulation output may not be able support a marker pulse output (e.g.
SC EnDat or SC SSI device types). Pr 03.086 shows the status of the encoder simulation output indicating whether the output is disabled, no marker
pulse is available or full encoder simulation is available.
When using the P1 and P2 position interfaces and the encoder simulation output together, the P2 position interface uses alternative connections on
the 15-way D-type connector. Pr 03.172 shows the status of the P2 position interface and indicates if alternative connections are being used for the
P2 position interface.
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NOTE
4.12.3 Position feedback connection details
Table 4-19 P1 Position feedback connection details
P1 Position
feedback
interface
Pr 03.038
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
AB (0) A A\ B B\ Z Z\
FD (1) F F\ D D\ Z Z\
FR (2) F F\ R R\ Z Z\
AB Servo (3) A A\ B B\ Z Z\ U U\ V V\ W W\
FD Servo (4) F F\ D D\ Z Z\ U U\ V V\ W W\
FR Servo (5) F F\ R R\ Z Z\ U U\ V V\ W W\
SC (6)
A
(Cos)A\(Cos\)B(Sin)B\(Sin\)
ZZ\
SC Hiperface (7) Cos Cosref Sin Sinref DATA DATA\
EnDat (8) DATA DATA\ CLK CLK\ Freeze Freeze\
SC EnDat (9) A A\ B B\ DATA DATA\ CLK CLK\
SSI (10) DATA DATA\ CLK CLK\ Freeze Freeze\
SC SSI (11)
SC Servo (12)
A
(Cos)A\(Cos\)B(Sin)B\(Sin\)
A
(Cos)A\(Cos\)B(Sin)B\(Sin\)
DATA DATA\
ZZ\UU\VV\WW\
BiSS (13) DATA DATA\ CLK CLK\ Freeze Freeze\
Resolver (14) Cos H Cos L Sin H Sin L Ref H Ref L
SC SC (15)
A
(Cos)A\(Cos\)B(Sin)B\(Sin\)
ZZ\
Commutation
Only (16)
SC BiSS (17)
A
(Cos)A\(Cos\)B(Sin)B\(Sin\)
DATA DATA\
*1 - One cosine wave per revolution
*2 - One sine wave per revolution
Greyed cells are for P2 position feedback connections or simulated encoder outputs.
Connections
CLK CLK\
1
C*
C\*1D*2D\*
2
Freeze2 Freeze2\
UU\VV\ W W\
CLK CLK\
+V 0V Th
Freeze and Freeze\ on terminals 5 and 6 are for Freeze input 1. Freeze2 and Freeze2\ on terminals 11 and 12 are for Freeze input 2.
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NOTE
Table 4-20 P2 Position feedback and encoder simulation output connection details
P1 Position
feedback
interface
Pr 03.038
P2 Position
feedback
interface
Pr 03.138
AB (1)
Encoder
Simulation
Output
Connections
56 7 8 9 10 1112
A A\ B B\ Z Z\
FD (2) F F\ D D\ Z Z\
AB (0)
FD (1)
FR (2)
SC (6)
SC Hiperface (7)
Resolver (14)
FR (3)
EnDat (4)
SSI (5)
BiSS (6)
None (0)
AB (1)
Disabled*
1
F F\ R R\ Z Z\
DATA DATA\ CLK CLK\ Freeze2 Freeze2\
AB
Asim Asim\ Bsim Bsim\ Zsim Zsim\
FD Fsim Fsim\ Dsim Dsim\ Zsim Zsim\
FR
SSI
Fsim Fsim\ Rsim Rsim\ Zsim Zsim\
DATAsim DATAsim\ CLKsim CLKsim\
A A\ B B\
FD (2) F F\ D D\
1
F F\ R R\
DATA DATA\ CLK CLK\
AB Asim
Asim\ Bsim Bsim\
SC EnDat (9)
SC SSI (11)
SC BiSS (17)
FR (3)
EnDat (4)
SSI (5)
BiSS (6)
Disabled*
FD Fsim Fsim\ Dsim Dsim\
None (0)
AB (1)
FD (2)
FR (3)
FR
SSI
Disabled*
Fsim Fsim\ Rsim Rsim\
DATAsim DATAsim\ CLKsim CLKsim\
A A\ B B\ Z Z\
F F\ D D\ Z Z\
1
F F\ R R\ Z Z\
EnDat (4)
EnDat (8)
SSI (10)
BiSS (13)
EnDat (8)
SSI (10)
BiSS (13)
(with no Freeze
inputs)
*1
The encoder simulation output is disabled when Pr 03.085 is set to zero.
SSI (5)
BiSS (6)
None (0)
EnDat (4)
SSI (5)
BiSS (6)
DATA DATA\ CLK CLK\ Freeze2 Freeze2\
AB
FD
Asim Asim\ Bsim Bsim\ Zsim Zsim\
Fsim Fsim\ Dsim Dsim\ Zsim Zsim\
FR Fsim Fsim\ Rsim Rsim\ Zsim Zsim\
SSI
DATAsim DATAsim\ CLKsim CLKsim\
AB DATA DATA\ Asim Asim\ Bsim Bsim\ CLK CLK\
FD DATA DATA\ Fsim Fsim\ Dsim Dsim\ CLK CLK\
FR DATA DATA\ Fsim Fsim\ Rsim Rsim\ CLK CLK\
SSI DATA DATA\ DATAsim DATAsim\ CLKsim CLKsim\ CLK CLK\
The termination resistors are always enabled on the P2 position interface. Wire break detection is not available when using AB, FD or FR position
feedback device types on the P2 position interface.
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NOTE
4.12.4 Position feedback terminal specifications
B, D, R Sinref, Clock, Sin H
A,F, Cosref, Data, Cos H
1
A\,F\ Cosref\, Data\, Cos L
2
AB (0), FD (1), FR (2), AB Servo (3), FD Servo(4), FR Servo (5
Type EIA-485 differential receivers
Maximum input frequency 500 kHz
Line loading
Line termination components
Working common mode range –7 V to +12 V
2 unit loads
120
(switchable)
)
SC Hiperface (7), SC EnDat (9), SC SSI (11), SC Servo (12),
SC SC (15), SC BiSS (17)
Type Differential voltage
Maximum Signal level
Maximum input frequency See Table 4-21
Maximum applied differential voltage and
common mode voltage range
Resolution: The sine wave frequency can be up to 500 kHz but the resolution is
reduced at high frequency. Table 4-21 shows the number of bits of interpolated
information at different frequencies and with different voltage levels at the drive
encoder port
1.25 V peak to peak (sin with
regard to sinref and cos with
regard to cosref)
4 V
EnDat (8), SSI (10), BiSS (13)
Type EIA-485 differential receivers
Maximum input frequency 4 MHz
Line termination components
Working common mode range –7 V to +12 V
120
(switchable)
Resolver (14)
Type 2 Vrms sinusoidal signal
Operating Frequency 6 - 8 kHz
Input voltage 0.6 Vrms
Minimum impedance
85
Common to All
Absolute maximum applied voltage relative to 0V
-9 V to 14 V
3
B\, D\, R\, Sinref\, Clock\, Sin L
4
AB (0), FD (1), FR (2), AB Servo (3), FD Servo(4), FR Servo (5
Type EIA-485 differential receivers
Maximum input frequency 500 kHz
Line loading
Line termination components
Working common mode range –7 V to +12 V
2 unit loads
120
(switchable)
SC Hiperface (7), SC EnDat (9), SC SSI (11), SC Servo (12),
SC SC (15), SC BiSS (17)
Type Differential voltage
1.25 V peak to peak (sin with
Maximum Signal level
Maximum input frequency See Table 4-21
Maximum applied differential voltage and
common mode voltage range
Resolution: The sine wave frequency can be up to 500 kHz but the resolution is
reduced at high frequency. Table 4-21 shows the number of bits of interpolated
information at different frequencies and with different voltage levels at the drive
encoder port
regard to sinref and cos with
regard to cosref)
4 V
EnDat (8), SSI (10), BiSS (13)
Type EIA-485 differential receivers
Maximum input frequency 4 MHz
Line termination components
Working common mode range –7 V to +12 V
120
(switchable)
Resolver (14)
Type 2 Vrms sinusoidal signal
Operating Frequency 6 – 8 kHz
Input voltage 0.6 Vrms
Minimum impedance
85
Common to All
Absolute maximum applied voltage relative to 0V -9 V to 14 V
)
Maximum
(with termination resistors enabled)
The position feedback input will accept 5 V TTL differential signals.
differential voltage between terminals
6 V
Maximum
(with termination resistors enabled)
differential voltage between terminals
6 V
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Z, Data, Freeze, Ref H
5
Z\, Data\, Freeze\, Ref L
6
AB (0), FD (1), FR (2), AB Servo (3), FD Servo(4), FR Servo (5
Type EIA-485 differential receivers
Maximum input frequency 512 kHz
Line loading
Line termination components
Working common mode range –7 V to +12 V
2 unit loads
120
(switchable)
),
SC SC (15)
SC Hiperface (7), SC EnDat (9), SC SSI (11), SC Servo (12),
SC BiSS (17)
Type EIA-485 differential receivers
Maximum input frequency 4 MHz
Line termination components
Working common mode range –7 V to +12 V
120
(switchable)
EnDat (8), SSI (10)
Type EIA-485 differential receivers
Maximum input frequency 4 MHz
Line termination components
Working common mode range –7 V to +12 V
120
(switchable)
Resolver (14)
Type Differential voltage
Nominal voltage
Operating frequency 6 - 8 KHz
Minimum impedance
0 – 2 Vrms depending on turns
ratio
85
U, C, Not used, Not used
7
U\, C\, Not used, Not used
8
AB Servo (3), FD Servo(4), FR Servo (5
Type EIA 485 differential receivers
Maximum input frequency 512 kHz
Line loading 1 unit load
Line termination components
Working common mode range –7 V to +12 V
), SC Servo (12)
120
(switchable)
SC SC (15)
Type Differential voltage
1.25 V peak to peak (sin with
Maximum Signal level
Maximum input frequency See Table 4-21
Maximum applied differential voltage and
common mode voltage range
regard to sinref and cos with
regard to cosref)
4 V
EnDat (8), SSI (10), BiSS (13)
Not used
Resolver (14)
Not used
Common to All
Absolute maximum applied voltage relative to 0V -9 V to 14 V
Maximum
differential voltage between terminals
(with termination resistors enabled)
6 V
Common to All
Absolute maximum applied voltage relative to 0V -9 V to 14 V
Maximum
differential voltage between terminals
(with termination resistors enabled)
6 V
V, D, Not used, Not used
9
V\, D\, Not used, Not used
10
AB Servo (3), FD Servo(4), FR Servo (5
Type EIA 485 differential receivers
Maximum input frequency 512 kHz
Line loading 1 unit load
Line termination components
Working common mode range –7 V to +12 V
), SC Servo (12)
(switchable)
120
SC SC (15)
Type Differential voltage
1.25 V peak to peak (sin with
Maximum Signal level
Maximum input frequency See Table 4-21
Maximum applied differential voltage and
common mode voltage range
regard to sinref and cos with
regard to cosref)
4 V
EnDat (8), SSI (10), BiSS (13)
Not used
Resolver (14)
Not used
Common to All
Absolute maximum applied voltage relative to 0V -9 V to 14 V
Maximum differential voltage between terminals
(with termination resistors enabled)
±6 V
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1
1
8
8
A
B
Table 4-21 Feedback resolution based on frequency and voltage level
W, Clock, Not used, Not used
11
W\, Clock\, Not used, Not used
12
AB Servo (3), FD Servo(4), FR Servo (5
Type EIA 485 differential receivers
Maximum input frequency 512 kHz
Line loading 1 unit load
Line termination components
Working common mode range –7 V to +12 V
), SC Servo (12)
(switchable)
120
SC EnDat (9), SC SSI (11)
Type Differential voltage
1.25 V peak to peak (sin with
Maximum Signal level
Maximum input frequency See Table 4-21
Maximum applied differential voltage and
common mode voltage range
regard to sinref and cos with
regard to cosref)
4 V
Volt/Freq 1 kHz 5 kHz 50 kHz 100 kHz 200 kHz 500 kHz
1.2 11 11 10 10 9 8
1.0111110997
0.8101010987
0.610109987
0.4999876
4.13 Communication connections
The Digitax HD M753 drive offers EtherCAT fieldbus communications
and the Digitax HD M751 drive offers a 2 wire EIA 485 interface. This
enables the drive set-up, operation and monitoring to be carried out with
a PC (Connect) or controller if required.
Figure 4-29 Location of the communication connectors
EnDat (8), SSI (10), BiSS (13)
Not used
Resolver (14)
Not used
Common to All
Absolute maximum applied voltage relative to 0V -9 V to 14 V
Maximum differential voltage between terminals
(with termination resistors enabled)
6 V
Common to all Feedback types
Feedback device supply
13
Supply voltage 5.15 V ±2 %, 8 V ± 5 % or 15 V ± 5 %
Maximum output current
The voltage on Terminal 13 is controlled by Pr 03.036. The default for this
parameter is 5 V (0) but this can be set to 8 V (1) or 15 V (2). Setting the encoder
voltage too high for the encoder could result in damage to the feedback device.
The termination resistors should be disabled if the outputs from the encoder are
higher than 5 V.
0V Common
14
Motor thermistor input
15
Thermistor type is selected in P1 Thermistor Type (03.118).
Sincos encoder resolution
The sine wave frequency can be up to 500 kHz but the resolution is
reduced at high frequency. Table 4-21 shows the number of bits of
interpolated information at different frequencies and with different
voltage levels at the drive encoder port. The total resolution in bits per
revolution is the ELPR plus the number of bits of interpolated
information. Although it is possible to obtain 11 bits of interpolation
information, the nominal design value is 10 bits.
300 mA for 5 V and 8 V
200 mA for 15 V
4.13.1 Digitax HD M753 EtherCAT fieldbus communications
The Digitax HD M753 has two RJ45 Ethernet ports for the EtherCAT
network, refer to Figure 4-29 Location of the communication connectors.
A: EtherCAT port 1.
B: EtherCAT port 2.
Cables should be shielded and as a minimum, meet TIA Cat 5e
requirements.
The shell of the RJ45 connector is capacitively coupled to ground.
Table 4-22 EtherCAT terminal descriptions
Pin EtherCAT port 1 - IN Pin EtherCAT port 2 - OUT
1 Transmit + 1 Transmit +
2 Transmit - 2 Transmit -
3 Receive + 3 Receive +
4 Not used 4 Not used
5 Not used 5 Not used
6 Receive - 6 Receive -
7 Not used 7 Not used
8 Not used 8 Not used
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CAUTION
WARNING
4.13.2 Digitax HD M751 EIA 485 serial communications
The EIA-485 interface provides two parallel RJ45 connectors allowing
easy daisy chaining, refer to Figure 4-29 Location of the communication
connectors on page 81. The drive supports Modbus RTU protocol. See
Table 4-23 for the connection details.
Standard Ethernet cables are not recommended for use when
connecting drives on a EIA-485 network as they do not have the correct
twisted pairs for the pinout of the serial comms port.
Table 4-23 Serial communication port pin-outs
Minimum number of connections are 2, 3, 7 and shield.
If an Ethernet network adaptor is inadvertently connected to
a Digitax HD M751 EIA-485 drive, a low impedance load
across the EIA-485 24 V is applied and if connected for a
significant period of time can introduce the potential risk of
damage.
Pin Function
1 120 Termination resistor
2RX TX
3 Isolated 0 V
4 +24 V (100 mA)
5 Isolated 0 V
6 TX enable
7RX\ TX\
8 RX\ TX\ (if termination resistors are required, link to pin 1)
Shell Isolated 0 V
4.13.3 Digitax HD M751 Isolation of the EIA-485 serial communications port
The serial communications port is double insulated from the high voltage
drive circuits and meets the requirements for PELV (Protective Extra
Low Voltage) according to IEC61800-5-1. The communications ports
remain referenced to other PELV rated circuits within the drive (including
the control, feedback and digital I/O). Where further isolation from these
PELV rated circuits is required and additional external isolation barrier
will be required.
In order to meet the requirements for SELV in IEC60950 (IT
equipment) it is necessary for the control computer to be
grounded. Alternatively, when a lap-top or similar device is
used which has no provision for grounding, an isolation
device must be incorporated in the communications lead.
An isolated serial communications lead has been designed to connect
the drive to IT equipment (such as laptop computers), and is available
from the supplier of the drive. See below for details:
Table 4-24 Isolated serial comms lead details
Part number Description
4500-0096 USB Comms cable
The “isolated serial communications” lead has reinforced insulation as
defined in IEC60950 for altitudes up to 3,000 m.
4.13.4 Communication networks and cabling
Any isolated signal circuit has the capability to become live through
accidental contact with other conductors; as such they should always be
double-insulated from live parts. The routing of network and signal wires
should be done so as to avoid close proximity to mains voltage cabling.
4.14 Safe Torque Off (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.
The safety function is active when the STO input is in the logic-low state
as specified in the control terminal specification. The function is defined
according to EN 61800-5-2 and IEC 61800-5-2 as follows. (In these
standards a drive offering safety-related functions is referred to as a
PDS(SR)):
'Power that can cause rotation (or motion in the case of a linear motor) is
not applied to the motor. The PDS(SR) will not provide energy to the
motor which can generate torque (or force in the case of a linear motor)'
This safety function corresponds to an uncontrolled stop in accordance
with stop category 0 of IEC 60204-1.
The Safe Torque Off function makes use of the special property of an
inverter drive with an induction motor, which is that torque cannot be
generated without the continuous correct active behaviour of the inverter
circuit. All credible faults in the inverter power circuit cause a loss of
torque generation.
Note on the use of servo motors, other permanent-magnet motors,
reluctance motors and salient-pole induction motors:
When the drive is disabled through Safe Torque Off, a possible
(although highly unlikely) failure mode is for two power devices in the
inverter circuit to conduct incorrectly.
This fault cannot produce a steady rotating torque in any AC motor. It
produces no torque in a conventional induction motor with a cage rotor.
If the rotor has permanent magnets and/or saliency, then a transient
alignment torque may occur. The motor may briefly try to rotate by up to
180° electrical, for a permanent magnet motor, or 90° electrical, for a
salient pole induction motor or reluctance motor. This possible failure
mode must be allowed for in the machine design.
The Safe Torque Off function is fail-safe, so when the Safe Torque Off
input is disconnected the drive will not operate the motor, even if a
combination of components within the drive has failed. Most component
failures are revealed by the drive failing to operate. Safe Torque Off is
also independent of the drive firmware. This meets the requirements of
the following standards, for the prevention of operation of the motor.
Machinery Applications
The Safe Torque Off function is suitable for use as a safety component
of a machine:
Safety Parameters
According to IEC 61508-1 to 7 / EN 61800-5-2 / EN 62061
Typ e Valu e
Proof test interval 20 years
High demand or a continuous mode of operation
PFH (1/h)
Low demand mode of operation (not EN 61800-5-2)
PFDavg
4.21 x 10
-11
3.68 x 10
Percentage of SIL
1/h
-6
3 allowance
<1 %
< 1 %
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WARNING
WARNING
WARNING
WARNING
According to EN ISO 13849-1
Type Value Classification
Category 4
Performance Level (PL) e
(STO1)
MTTF
D
MTTF
(STO2)
D
MTTF
(Single channel
D
STO)
DC
avg
>2500 years High
>2500 years High
>2500 years High
≥99 % High
Mission time 20 years
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.
Safe Torque Off inhibits the operation of the drive, this
includes inhibiting braking. If the drive is required to provide
both braking and Safe Torque Off in the same operation (e.g.
for emergency stop) then a safety timer relay or similar device
must be used to ensure that the drive is disabled a suitable
Logic levels comply with IEC 61131-2:2007 for type 1 digital inputs rated
at 24 V. Maximum level for logic low to achieve SIL3 and PL e 5 V and
0.5mA.
time after braking. The braking function in the drive is
provided by an electronic circuit which is not fail-safe. If
braking is a safety requirement, it must be supplemented by
an independent fail-safe braking mechanism.
Two-channel Safe Torque Off
Models Digitax HD M75X have dual channel STO.
The dual channel STO has two fully independent channels.
Each input meets the requirements of the standards as defined above.
Safe Torque Off does not provide electrical isolation.
The supply to the drive must be disconnected by an approved
isolation device before gaining access to power connections.
If either or both inputs are set at a logic low state, there are no single
faults in the drive which can permit the motor to be driven.
It is not necessary to use both channels to meet the requirements of the
standards. The purpose of the two channels is to allow connection to
machine safety systems where two channels are required, and to
facilitate protection against wiring faults.
For example, if each channel is connected to a safety-related digital
output of a safety related controller, computer or PLC, then on detection
It is essential to observe the maximum permitted voltage of
5 V for a safe low (disabled) state of Safe Torque Off. The
connections to the drive must be arranged so that voltage
drops in the 0V wiring cannot exceed this value under any
loading condition. It is strongly recommended that the Safe
Torque Off circuit be provided with a dedicated 0V conductor
which should be connected to either terminals 1, 3, 4, 5, 7 or
15 at the drive.
of a fault in one output the drive can still be disabled safely through the
other output.
Under these conditions, there are no single wiring faults which can
cause a loss of the safety function, i.e. inadvertent enabling of the drive.
In the event that the two-channel operation is not required, the two
inputs can be connected together to form a single Safe Torque Off input.
One-channel Safe Torque Off (Including Two- channel Safe Torque
off with the inputs connected together.)
In a single channel Safe torque Off application there are no single faults
in the drive which can permit the motor to be driven. Therefore it is not
necessary to have a second channel to interrupt the power connection,
Safe Torque Off over-ride
The drive does not provide any facility to over-ride the Safe Torque Off
function, for example for maintenance purposes.
Lift (Elevator) Applications
The Safe Torque Off function is suitable for use as a safety component
in lift (elevator) applications:
The Safe Torque Off function can be used to eliminate electromechanical contactors, including special safety contactors, which would
otherwise be required for safety applications.
For further information, contact the supplier of the drive.
nor a fault detection circuit.
It is important to note that a single short-circuit from the Safe Torque Off
input to a DC supply of > 5V could cause the drive to be enabled.
This might occur through a fault in the wiring. This can be excluded
according to EN ISO 13849-2 by the use of protected wiring. The wiring
can be protected by either of the following methods:
• By placing the wiring in a segregated cable duct or other enclosure.
Or
• By providing the wiring with a grounded (0V of the Drive) shield in a
positive-logic grounded control circuit. The shield is provided to avoid a
hazard from an electrical fault. It may be grounded by any convenient
method; no special EMC precautions are required.
Note on response time of Safe Torque Off, and use with safety
controllers with self-testing outputs:
Safe Torque Off has been designed to have a response time of greater
than 1 ms so that it is compatible with safety controllers whose outputs
are subject to a dynamic test with a pulse width not exceeding 1 ms.
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NOTE
5 Multi axis system design
There are a number of important considerations for multi axis systems, it is recommended that the design process follows the following method:
1. Determine the power profile of the system and select the most appropriate parallel DC bus, drive and motor configuration to meet the demands of
the power profile (refer to section 5.1 below).
2. Assess DC bus paralleling connection method, external 24 Vdc, dynamic braking, EMC filter and fieldbus communication requirements, refer to
section 5.2 DC bus paralleling connection method on page 87 to section 5.6 EMC filters for multi axis systems on page 91
3. Choose the mechanical installation method, refer to section 5.7 Multi axis system installation on page 92.
An example applying these steps is given in section 5.8 Example design of a multi axis system on page 95.
5.1 Multi axis system power profile and configuration
The power profile of one complete worst case duty cycle should be calculated in watts from the product of rated speed (radians/sec) and torque (Nm)
for each axis. The sum total instantaneous power of the all axis over one complete duty cycle should also be calculated.
Individual drives should be selected to meet the power requirements of each axis.
The power profile of the whole system (including all axis) should be used to determine which DC paralleling configuration is the most suitable.
5.1.1 DC bus paralleling configuration
Connecting the DC links of several drives together allows regenerated/braking energy from one drive to be re-used by another motoring drive. This
improves the efficiency of the system since the regenerated energy is not wasted in braking resistors and the motoring drive draws substantially less
power from the mains. This can be particularly advantageous where one or more drives may be 'holding back' a line to provide tension. It is often
applied in high performance servo drive applications where substantial amounts of energy is used in accelerating and braking motors/machines.
As well as offering advantages in terms of simplifying energy management, a common DC bus system also has the potential to simplify the mains
connections and protection.
The following parallel DC bus configurations cover single AC mains feed only.
There are a number of different ways of connecting Digitax HD M75X drives together and paralleling the DC bus.
5.1.2 DC paralleling using a Digitax HD M75X rectifier to provide the DC supply
In this configuration multiple drives can be connected together via a parallel DC bus from a single AC feed to create a frame block. A frame block can
be comprised of Digitax HD M75X series drives of different frame sizes and current ratings.
Drives of different voltage ratings cannot be mixed on the same frame block.
Only one AC input should be connected to a system using a common DC bus.
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4
5
1
2
Optional
EMC filter
Figure 5-1 Digitax HD M75X AC fed mixed frame block
1. Digitax HD M75X rectifier supplying a parallel DC bus. 2. DC busbars (supplied with Multi axis kits).
3. Ground busbar (supplied with Multi axis kits). 4. Communications link (supplied with Multi axis kits).
5. 24 Vdc link (supplied with Multi axis kits).
Two multi axis kit variants are available from the supplier of the drive; (i) for drives without
Option Module Mounting kit fitted.
Refer to Section 2.8.1 Installation and system accessory kits available with Digitax HD M75X series for more information on multi axis kits.
Maximum frame block size
The maximum size of any Digitax HD M75X frame block configuration is 10 drives but may be reduced depending on the maximum frame block
capacitance that a Digitax HD M75X rectifier can support.
Maximum continuous input power
Each Digitax HD M75X series drive has an internal rectifier which has been designed to allow more input power than a single axis drive needs. This
additional power capability provides a useful method to provide a DC supply for additional drives connected via a common DC bus. The maximum
input power depends on the frame size and voltage rating. When the parallel DC bus consists of a mix of frame sizes, the largest frame size should be
chosen as the Digitax HD M75X rectifier drive.
SI-Option Module Mounting kit fitted or (ii) for drives with SI-
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Each Digitax HD M75X drive has its own inrush current limitation circuit; therefore no additional inrush circuit is required.
The worst case output power requirement for the whole system must be compared with the maximum continuous AC input power of the drive chosen
with the AC connection (Digitax HD M75X rectifier), refer to Table 5-1 Multi axis AC input ratings.
To prevent the Digitax HD M75X rectifier from being overloaded, the worst case system output power demand from all axes, must not
exceed the maximum continuous AC input power of the Digitax HD M75X rectifier at any time.
Where the maximum continuous AC input power of the Digitax HD M75X rectifier is exceeded, additional frame blocks will be required.
Table 5-1 Multi axis AC input ratings
Digitax HD
M75X frame
size
1
2 5.3 35.4 1160 4640
3
1
2 8.7 34.5 290 2030
3
* An AC line reactor can be used to extend the power rating of the drives, a suitable line reactor is available from the supplier of the drive, refer to
Table 5-2.
Table 5-2 Digitax HD M75X line reactor
Part
number
4401-0236 INL4013 32 0.48 4.9 102 156 146
Voltage range
200 V
400 V
Line reactor
designation
Max continuous AC
input power
kW A uF uF
4 23.2 580 5800
6.3 37.9
10* 37.9
6.5 23.9 110 1900
10 39.1
13* 39.1
Line reactor
current rating
Amh kg mm mmmm
Inductance Weight Length Width Height
Maximum input current
Internal drive DC
capacitance
(a)
1880 3760
470 2210
Maximum frame block
capacitance when AC
source (b)
Maximum frame block capacitance
When creating a frame block with Digitax HD M75X drives of multiple frame sizes, the maximum frame block capacitance (b) that the Digitax HD
M75X rectifier can support should be greater than the sum of all the individual internal drive DC capacitance values (a) within the same frame block.
If more drives are required for an application than a single frame block will allow, then multiple separate frame blocks each with an individual Digitax
HD M75X rectifier can be created.
Input cable and fusing
No supplemental DC fuses are required for this type of configuration.
When a Digitax HD M75X drive is used as a AC supply for a frame block, only AC branch protection fuses are required. The maximum fuse which can
be used to protect the system is given in Table 5-3. Smaller fuses and input cables can be used provided the fuse is from the same range and
dimensioned for the required input power. If the input cable is smaller than that listed in Table 5-3 the protection fuse must be reduced accordingly.
Table 5-3 Maximum fuse and minimum cable size for AC converter
Model
All 40 40 6 8
When the AC input power is known, the following formula can be used to estimate the suitable input current for cable and fuse selection.
Input current (A)= a x P(kW)
Where constants a, b and c are given in Table 5-4:
Table 5-4 Input current equation constants
2
+b x P(kW)+c
Fuse rating Fuse rating Input cable size
IEC class gG UL class J
mm
2
AWG
Constant 200 V drives, 3 phase 400 V drives, 3 phase 200 V drives, single phase
a -0.55 -0.2 -0.5
b9.7 6 11
c0.2 0.5 0
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NOTE
NOTE
5.1.3 DC paralleling fed from a separate DC source such as a rectifier stack or larger drive from the Digitax
HD range
There are a number of advantages in using this method of DC paralleling:
• Allows drives of different frame sizes to be connected together.
• Reduces AC supply side component parts.
• Reduces energy losses (heat loss from braking resistors).
There are limitations to the combinations of drives which can be used in this configuration. For further information, contact the supplier of the drive.
5.2 DC bus paralleling connection method
DC bus paralleling using standard cable/busbars is supported by all frame sizes in the Digitax HD M75X range.
5.2.1 DC paralleling with busbars
The terminal and enclosure design enables the DC bus of a number of drives to be connected together using pre-made busbars. Suitable busbar
links for DC paralleling are included in multi axis kits available from the supplier of the drive; refer to Table 5.3 External 24 Vdc supply requirements for
multi axis systems.
Table 5-5 Multi axis kit part numbers
Model Description Part number
All
Multi axis kits are not supplied with the drive but available to order from the supplier of the drive.
The diagram below shows how the DC and ground busbar links should be used to connect several drives together. For access to the drive DC bus
terminal refer to section 4.3.1 DC terminal cover access/removal on page 51.
Figure 5-2 Parallel DC bus and ground connections using busbar links (DC bus cover removed for clarity)
Multi axis kit (standard - no option module) 9500-1047
Multi axis kit (with option module) 9500-1048
The DC busbar system is rated at 60 A continuous.
DC terminal cover breakout tabs must not be removed when connecting multi axis drives using pre-made busbars supplied in the multi axis kits.
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WARNING
1
2
5.2.2 DC paralleling with cables
DC supply cables up to 6 mm2 (AWG 10) can be connected directly to the DC terminals with a suitably insulated M4 ring crimp. The DC terminal
cover breakout tab (1) only needs to be removed when a DC drive supply is made with cable connections. DC terminal cover breakout tabs do not
need to be removed when connecting multi axis drives using pre-made busbars supplied in the multi axis kits.
Figure 5-3 DC supply connections and cable routing
DC cable grommets must be fitted when DC terminal cover breakout tabs are removed. Suitable grommets are available from the supplier
of the drive. Refer to section 2.8.1 Installation and system accessory kits available with Digitax HD M75X series on page 14.
Larger external DC supply cables for multi axis installations (6 mm
refer to section 2.8.1 Installation and system accessory kits available with Digitax HD M75X series on page 14.
Figure 5-4 External DC bus cable connection kit - Installation step 1
2
to 16 mm2) can be accommodated using an external DC bus cable connection kit;
• Attach the base assembly of the External DC bus cable connection kit to the drive (1).
• Secure the DC busbar terminals with the M4 screws (2) supplied wit the drive.
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1
1
1
2
Figure 5-5 External DC bus cable connection kit - Installation step 2
• Connect the DC cables to the terminal studs of the External DC bus cable connection kit (1) and secure using the M5 nuts provided. Tools
required - M8 socket and torque wrench, torque 4 N m (35.4 lb in).
Figure 5-6 External DC bus cable connection kit - Installation step 3
• Slide the DC bus cable connection cover into position (1) and secure the DC terminal cover.
Where a single AC feed is used to supply multiple drives DC paralleled via cables, the AC supply fuses will also protect the DC supply cables if the
DC cables are rated for the AC fuse current rating multiplied by a factor to account for the difference between AC and DC supply current.
The DC cables should be rated for the AC fuse rating x 1.25.
Where this is not possible, additional protection for the DC cables should be considered.
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NOTE
1
2
NOTE
5.3 External 24 Vdc supply requirements for multi axis systems
External 24 Vdc link
For a multi axis system, the installation time and cable requirements can be reduced by using the 24 V links supplied in each multi axis kit. Each kit
includes one 24 Vdc busbar link which provides a quick method of connecting 24 Vdc between 2 drives.
A maximum of 10 drives can be connected together using 24 V links.
Figure 5-7 24 V busbar link (multi axis kit with option module)
• The 24 Vdc busbar link (1) is a push fit connection which should be inserted adjacent to the 24 Vdc supply connector (2). The 24 Vdc supply
connector can be fitted to either outermost drive.
If the drive is required to attempt a controlled motor stop during a mains supply loss condition, then the external 24 Vdc must be maintained for at
least as long as the drive remains active.
Calculating the external 24 Vdc supply requirements
The external 24 Vdc supply should be sized using the maximum input current and power demand referenced in Table 5-6, sum currents/power based
on configuration.
The working voltage range of the 24 V power supply is as follows:
All frame sizes
Nominal operating voltage 24.0 Vdc
Minimum continuous operating voltage 20.4 V
Maximum continuous operating voltage 28.8 V
Minimum start up voltage 20.4 V
Maximum fuse rating 30 A
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NOTE
1
Table 5-6 24 Vdc typical input current and power requirements
Model / Option / Feature Frame size
Digitax HD M75X drive module
SI-option module Per module 450 11
High current brake output All 1200 28.8
KI-Compact display All 10 0.24
KI-Remote LCD keypad All 73 1.75
During start up of the external 24 Vdc supply, allow for an additional 1 A for 300 ms.
1 and 2 894 21.5
3 1039 25
Typical input current (mA)
@ 24 V
Typical input power
5.4 Communications link
Each multi axis kits also includes a communications link, this is a pre-wired cable assembly which provides easy connection between
communications modules.
Figure 5-8 Communications link connection
1. Communications link
5.5 Brake operation for multi axis systems
Where multiple brake resistors are required to dissipate energy on the DC bus it may be necessary to vary the brake IGBT turn on threshold via
Braking IGBT Lower Threshold (Pr 06.073) to avoid excess ripple on the DC bus. Care should be taken when reducing the threshold however to
avoid going below the maximum value of the peak rectified supply voltage as the braking resistor could take power from the supply.
For further details refer to the relevant Parameter Reference Guide.
5.6 EMC filters for multi axis systems
External EMC filters with higher input current ratings suitable for multi axis systems are detailed in Table 4-15 External EMC filter ratings on page 62.
Refer to the input current equation given in section 5.1.2 DC paralleling using a Digitax HD M75X rectifier to provide the DC supply on page 84 to size
the EMC filter.
For more information, refer to the Digitax HD M75X series EMC datasheet available from the supplier of the drive.
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62 mm (2.44 in)* 62 mm (2.44 in)*
40 mm (1.58 in)
5.7 Multi axis system installation
Direct side by side mounting is permissible between drives to minimize space requirement and allow for easy connectivity.
5.7.1 Multiple drive mounting
Figure 5-9 Multiple drive mounting
* Allow for up to +0.5 mm mechanical tolerance for each drive with option module support installed.
Mounting screws
For multi axis (side by side installation) with no
mounting position for each drive.
DIN rail attachment, one M5 screw is required in the top mounting position and one in the lower
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CAUTION
1
2
5.7.2 DIN rail alignment
DIN rail assembly is recommended with multi axis systems to align the DC power and ground busbar links, 24 Vdc link and communication link.
Drives may be hooked onto the DIN rail, a recess is provided at the rear of the drive for this function. DIN rail should meet the following designation:
Top hat rail EN 50022-35x7.5.
The DIN rail attachment is for alignment only and must not be used alone for drive mounting. Refer to Section 5.7.3 Drive mounting
dimensions with DIN rail alignment.
Figure 5-10 DIN rail alignment
• Fit the drive over the DIN rail with the bottom rail flush against the lower edge of the recess at the rear of the drive (1).
• Slide the drive down so that the top rail sits into the channel at the upper edge of the recess at the rear of the drive (2).
Mounting screws
For multi axis (side by side installation) with DIN rail attachment one M5 screw in the top mounting position is sufficient to fix the drive to the
backplate.
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40 mm (1.58 in)
Æ5.4 mm (0.21 in)
(M5)
Æ32 mm (1.26 in)
*
28 mm (1.10 in)
35 mm (1.38 in)
5.0 mm
(0.20 in)
222 mm (8.74 in)
233 mm (9.17 in)
272 mm (10.71 in)
278 mm (10.95 in)
322 mm (12.68 in)
328 mm (12.91 in)
92 mm (3.62 in)
109 mm (4.29 in)
40 mm (1.58 in)
Frame 1 Frame 2 Frame 3
5.7.3 Drive mounting dimensions with DIN rail alignment
Directly side by side mounting is permissible with no space required between drives.
Figure 5-11 Drive mounting dimensions with DIN rail alignment (no option module support)
* Cut outs only required for rear venting; refer to Section 3.9 Rear venting.
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Æ5.4 mm (0.21 in)
(M5)
Æ32 mm (1.26 in)
*
92 mm (3.62 in)
110 mm (4.33 in)
62 mm (2.44 in)
**
Frame 1 Frame 2 Frame 3
NOTE
Figure 5-12 Drive mounting dimensions with DIN rail alignment (with option module support)
* Cut outs only required for rear venting; refer to section 3.9 Rear venting on page 28.
** Allow for up to +0.5 mm tolerance between with each drive fitted with an option module mounting frame.
Mounting screws
For multi axis installation without DIN rail each drive should be secured by one M5 screw in the top mounting position and one M5 screw in the lower
mounting position.
For multi axis installation with DIN rail attachment each drive should be secured with one M5 screw in the top mounting position only.
5.8 Example design of a multi axis system
A four axis system operates with the power profiles and layout detailed in Figure 5-13 and Table 5-7. Each axis is controlling a different torque profile.
All drives are to be connected via an EtherCAT network and two drives will have SI option modules fitted.
STEP 1 - Determine the power profile of the system
The worst case output current and speed profiles for each axis are calculated and plotted. Individual power and sum total power for all axis are also
plotted in Figure 5-13.
STEP 2 - Select the most appropriate configuration to meet the demands of the power profile
The power profile plot of the total system demonstrates that the peak power demand is 9.6 kW.
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3
4
5
1
2
Optional
EMC filter
Axis D
Axis C
Axis B
Axis A
0
5
10
15
20
25
30
35
40
45
0 0.5 1 1.5 2 2.5 3
Current (A)
Time (s)
Current vs Time
Axis A
Axis B
Axis C
Axis D
-60
-40
-20
0
20
40
60
0 0.5 1 1.5 2 2.5 3
Speed (Hz)
Time (s)
Speed vs Time
Axis A
Axis B
Axis C
Axis D
-8
-6
-4
-2
0
2
4
6
8
10
12
0 0.5 1 1.5 2 2.5 3
Power (kW)
Time (s)
Power vs Time
Axis A
Axis B
Axis C
Axis D
Total Power
Figure 5-13 Layout output current, speed and power profile
With reference to section 2.4 Ratings on page 10, the drives listed in Table 5-7 meet the individual power and current profiles for each axis.
The total peak power demanded from the multi axis system is 9.6 kW, with reference to Table 5-1 Multi axis AC input ratings on page 86, this is within
the maximum continuous AC input power of the M753-03400160 selected for axis 4.
The total DC bus capacitance for all drives selected is 980 F, see Table 5-7 application example. The maximum frame block capacitance for an
M753-03400160 with no line reactor is 2210 F, see Table 5-1 Multi axis AC input ratings on page 86.
The M753-03400160 can therefore be used as the AC source with all drives connected as one frame block via a parallel DC bus.
As the AC input current remains within 40 A and no supplemental DC fuses are required, three 40 A LPJ fuses in the AC branch would be sufficient.
Table 5-7 Application example
Axis name
Motor current Output power Internal capacitance
AkW
F
Axis A - M753-01400042 0 to 12.6 0 to 6.69 110
Axis B - M753-01400042 0 to 12.6 -6.69 to 0 110
Axis C - M753-02400105 5 to 25 -0.8 to 8.7 290
Axis D - M753-03400160 0 to 40 0.0 to 4.28 470
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STEP 3 - Calculate the external 24 Vdc supply requirements, EMC filter required and quantity of Multi axis kits
needed
With reference to Table 5-7 24 Vdc typical input current and power requirements, the external 24 V current demand will be:
Table 5-8 24 V supply requirements for application example
Axis / Model / Option
Axis A - M753-01400042 894 21.5
Axis B - M753-01400042 894 21.5
Axis C - M753-02400105 894 21.5
Axis D - M753-03400160 1039 25
Option module x 2 900 22
Total 4621 111.5
EMC filter
The external EMC filter can be selected by input current rating using the following formula:
Input current (A) = a x P(kW)
Where constants a, b and c are given in Table 5-9:
Table 5-9 Input current equation constants
Constant 200 V drives, 3 phase 400 V drives,3 phase 200 V drives, single phase
Input current (A) = -0.2 x 9.6
Input current (A) = 39.67
Suitable external EMC filter (refer to Table 6-37 Optional external EMC filter details on page 113):
4200-3233 (46 A)
2
+ b x P(kW) + c
a -0.55 -0.2 -0.5
b 9.7 6 11
c 0.2 0.5 0
2
+ 6 x 9.6 + 0.5
Typical input current Typical input power
mA @ 24 V W
Multi axis kits
As both the M753-02400105 and M753-03400160 (axis C and axis D respectively) require SI-option modules and axis A and B do not, the following
multi axis kits are required:
Axis Kit
Axis D - M753-03400160 9500-1048 (Multi axis kit with SI-Option Mounting kit fitted)
Axis C - M753-02400105 9500-1048 (Multi axis kit with SI-Option Mounting kit fitted)
Axis B - M753-01400042 9500-1047 (Multi axis kit without SI-Option Mounting kit fitted)
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0.1 1 10
Normalised Irms
Time for Ipk (s)
Ipk, 8 kHz, 50/60 Hz
50/60 Hz 8 kHz 50/60 Hz, 8 kHz, Rear Duct Ipk, 8 kHz, 50/ 60 Hz, 50 C°
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0.1 1 10
Normalised Irms
Time for Ipk (s)
Ipk, 8 kHz, 0.1 Hz
6 Technical data
6.1 Drive technical data
6.1.1 Peak current duration for pulse duty applications
The maximum duration for the peak output current depends on the total rms output current for the complete profile. The curves illustrated in Figure 61 to Figure 6-3 can be used to determine the maximum duration for the drive peak current when operating at different rms currents. The curves are
shown normalised to the drive nominal current rating in a 40 °C ambient.
For example when using the Digitax HD M75X - 01400042
Nominal current = 4.2 A, Peak current = 12.6 A
• When operating at an output current of 4.2 A (1 on the curve), the peak current 12.6 A is available for 0.25 s.
• If the peak current of 12.6 A is required for 4 seconds, the maximum normalised r.m.s. current is 0.5 x 4.2 = 2.1 A.
• If the peak current of 12.6 A is required for 8 seconds, the current preceding the overload should be 0 A for at least 60 seconds (i.e. overload
is only available from the cold condition).
Figure 6-1 Maximum duration for 300 % overload @ 8 kHz switching frequency, 40 °C ambient and 50/60 Hz output frequency
Figure 6-2 Maximum duration for 300 % overload @ 8 kHz switching frequency, 40 °C ambient and 0.1 Hz output frequency
A reduction in the peak current will extend the overload duration, the maximum duration for a 200 % and 150 % overload can be determined from
Figure 6-3.
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0.01 0.1 1 10 100
Normalised Irms
Time for Ipk (s)
Time for Ipk
2 x In 1.5 x In
NOTE
Figure 6-3 Maximum duration for 200 % and 150 % overload @ 8 kHz switching frequency, 40 °C ambient and 50 Hz output frequency
6.1.2 Open loop and RFC-A ratings
Table 6-1 200 V drive ratings (200 V to 240 V ±10 %)
Heavy Duty
Model
Maximum continuous
output current
AAA kWhp
01200022 2.2 3.3 6.6 0.37 0.5
01200040 4.0 6.0 12.0 0.75 1.0
01200065 6.5 9.8 19.5 1.1 1.5
02200090 9.0 13.5 27.0 2.2 2.0
02200120 12.0 18.0 36.0 2.2 3.0
03200160 16.0 24.0 48.0 4.0 5.0
Open loop peak
current
RFC-A peak current Nominal power at 230 V Motor power at 230 V
Table 6-2 400 V drive ratings (380 V to 480 V
In continuous applications, the maximum allowed power may override the maximum allowable current when the motor power factor is greater than
0.87.
±10 %)
Heavy Duty
Open
loop
peak
current
RFC-A peak
current
Nominal
power
at 400 V
Motor
power
at 460 V
Model
Maximum
continuous
output
current
AAA kWhp
01400015 1.5 2.3 4.5 0.37 0.75
01400030 3.0 4.5 9.0 0.75 1.5
01400042 4.2 6.3 12.6 1.5 2.0
02400060 6.0 9.0 18.0 2.2 3.0
02400080 8.0 12.0 24.0 3.0 5.0
02400105 10.5 15.8 31.5 4.0 5.0
03400135 13.5 20.3 40.5 5.5 7.5
03400160 16.0 24.0 48.0 5.5 10.0
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NOTE
Typical short term overload limits
The maximum percentage overload limit changes depending on the selected motor. Variations in motor rated current, motor power factor and motor
leakage inductance all result in changes in the maximum possible overload. The exact value for a specific motor can be calculated using the
equations detailed in Menu 4 in the relevant Digitax HD M75X Parameter Reference Guide.
Typical values are shown in the table below for RFC-A, RFC-S and open loop (OL) modes:
RFC from cold RFC from 100 % Open Loop from cold Open Loop from 100 %
Heavy duty overload with motor rated
current = drive rated current
Generally the drive rated current is higher than the matching motor rated current allowing a higher level of overload than the default setting. The time
allowed in the overload region is proportionally reduced at very low output frequency on some drive ratings.
The maximum overload level which can be attained is independent of the speed.
300 % for 8 s or
200 % for 60 s
300 % for 0.25 s or
200 % for 4 s
150 % for 100 s 150 % for 8 s
Drives are rated up to 55
Table 6-3 Open loop and RFC-A maximum permissible continuous output current @ 40 °C (104 °F) ambient
Model
200 V
01200022 0.37 0.5 2.2 2.2 2.2
01200040 0.75 1.0 4.0 4.0 4.0
01200065 1.1 1.5 6.5 6.5 6.5
02200090 2.2 2.0 9.0 9.0 9.0
02200120 2.2 3.0 12.0 12.0 12.0
03200160 4.0 5.0 16.0 16.0 16.0
400 V
01400015 0.37 0.75 1.5 1.5 1.5
01400030 0.75 1.5 3.0 3.0 3.0
01400042 1.5 2.0 4.2 4.2 3.5
02400060 2.2 3.0 6.0 6.0 6.0
02400080 3.0 5.0 8.0 8.0 7.4
02400105 4.0 5.0 10.5 9.1 7.4
03400135 5.5 7.5 13.5 13.1 10.9
03400160 5.5 10.0 16.0 13.1 10.9
°C (131 °F) . 55 °C
Nominal rating
kW hp 2 kHz 3 kHz 4 kHz 6 kHz 8 kHz 12 kHz 16 kHz
(131 °F)
ratings are available from the supplier of the drive.
Heavy Duty
Maximum permissible continuous output current (A) allowing for 175 % overload for
4.5 s
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