Unico 11100, 1110, 1105, 1130, 1200 Installation And Troubleshooting Manual

...
11100 / 1105 / 1110 / 1120 / 1130 / 1200 / 1230
Variable-Frequency AC Drives
Troubleshooting,
and Maintenance
11/2 to 1,000 hp
(1.1 to 750 kW)
For revisions ECL 10 and above
Notices
Copyright © 2000-2013 by Unico, Incorporated.
All rights reserved. No part of this publication may be copied, reproduced, or reduced to any electronic media or machine-readable format without the prior written permission of Unico, Inc.
The information contained in this manual is considered accurate to the best knowledge of the supplier at the time of publication. The manufacturer, however, assumes no liability for errors that may exist. The supplier reserves the right to change data and specifications without notice.
All trade designations are provided without reference to the rights of their respective owners.
Printed in the United States of America.
110941 ECL 007
1000.40–07 6/13
Table of Contents
Table of Contents
Table of Contents ............................................................................................. 1-1!
Safety Information ................................................................................................ i!
Overview .............................................................................................................................. i!
Conventions Used ................................................................................................................ i!
General Precautions ............................................................................................................ ii!
Installation Precautions ...................................................................................................... iii!
Application Precautions ..................................................................................................... iii!
Service Precautions ............................................................................................................ iv!
1! About the Manual ....................................................................................... 1-1!
1.1! Overview ................................................................................................................ 1-1!
1.2! Contents ................................................................................................................. 1-1!
1.2.1! Intended Audience ............................................................................................. 1-2!
2! Product Overview ....................................................................................... 2-1!
2.1! Overview ................................................................................................................ 2-1!
2.2! Unpacking .............................................................................................................. 2-1!
2.2.1! Lifting Instructions ............................................................................................ 2-1!
2.2.2! Verify delivery ................................................................................................... 2-2!
2.2.3! Inspect for damage ............................................................................................ 2-2!
2.2.4! Storage/Transportation ...................................................................................... 2-2!
2.2.5! Nameplate Identification ................................................................................... 2-2!
2.3! Family Overview .................................................................................................... 2-3!
2.3.1! Features .............................................................................................................. 2-3!
2.3.2! Drive Architecture ............................................................................................. 2-6!
2.4! Specifications ......................................................................................................... 2-9!
3! Mechanical Installation .............................................................................. 3-1!
3.1! Overview ................................................................................................................ 3-1!
3.2! Forms ..................................................................................................................... 3-1!
3.3! Installation Site Considerations ............................................................................. 3-1!
3.3.1! Enclosure ........................................................................................................... 3-1!
3.3.2! Operating Environment ..................................................................................... 3-2!
3.3.3! Cooling .............................................................................................................. 3-2!
3.4! Layout Considerations ........................................................................................... 3-3!
3.4.1! Dimensions and Weights ................................................................................... 3-3!
3.4.2! Space Requirements .......................................................................................... 3-3!
3.4.3! Orientation ......................................................................................................... 3-3!
3.4.4! Cable Routing .................................................................................................... 3-3!
3.5! Installation Procedure ............................................................................................ 3-4!
3.5.1! Foot Mounting ................................................................................................... 3-4!
3.5.2! Flush Mounting (Form 22X) ............................................................................. 3-5!
3.5.3! Flange Mounting ............................................................................................... 3-5!
3.6! Mounting the I/O Fanning Strip ............................................................................. 3-5!
1000 Series / Guide to Installation, Troubleshooting, and Maintenance
4! Electrical Installation ................................................................................. 4-1!
4.1! Overview ................................................................................................................ 4-1!
4.2! Wiring Requirements ............................................................................................. 4-1!
4.2.1! Standards and Codes .......................................................................................... 4-1!
4.2.2! Conductors ......................................................................................................... 4-1!
4.2.3! Tightening Torque ............................................................................................. 4-1!
4.3! Insulation Tests ...................................................................................................... 4-2!
4.4! Ground Connections .............................................................................................. 4-2!
4.4.1! Ground the drive ................................................................................................ 4-3!
4.4.2! Ground the Power Supply ................................................................................. 4-3!
4.4.3! Ground the Motor and Transducer .................................................................... 4-3!
4.4.4! Connect the Control Grounds ............................................................................ 4-3!
4.5! Input Power Supply ................................................................................................ 4-3!
4.5.1! Power Source Conditioning ............................................................................... 4-4!
4.5.2! Connect the Power Supply .............................................................................. 4-18!
4.5.3! Input Protection ............................................................................................... 4-18!
4.6! Connect the Motor ............................................................................................... 4-18!
4.7! Connect the Dynamic Braking Resistor ............................................................... 4-19!
4.8! Bus Connections .................................................................................................. 4-20!
4.8.1! Common-Bus Operation .................................................................................. 4-20!
4.9! Control Signal Connections ................................................................................. 4-47!
4.9.1! Wiring Precautions .......................................................................................... 4-47!
4.9.2! Digital I/O Connections (TB1) ........................................................................ 4-51!
4.9.3! Analog I/O Connections (TB2, CON2) ........................................................... 4-52!
4.9.4! Serial Connections (TB1, J1, J2, J3, J4, J6, J11, J12) ..................................... 4-52!
4.9.5! Feedback Interface Connections ...................................................................... 4-53!
5! Troubleshooting/Maintenance .................................................................. 5-1!
5.1! Overview ................................................................................................................ 5-1!
5.2! Troubleshooting ..................................................................................................... 5-1!
5.2.1! Theory of Operation .......................................................................................... 5-1!
5.2.2! Rectifier Checking Procedure .......................................................................... 5-17!
5.2.3! Transistor Checking Procedure ....................................................................... 5-18!
5.3! Maintenance ......................................................................................................... 5-20!
5.3.1! Working Life ................................................................................................... 5-20!
5.3.2! Battery Life ...................................................................................................... 5-20!
5.3.3! Disposal ........................................................................................................... 5-20!
5.4! Parts and Repairs .................................................................................................. 5-20!
5.4.1! Parts ................................................................................................................. 5-20!
5.4.2! Repairs ............................................................................................................. 5-21!
Safety Information i
Safety Information
Overview
This section states important safety information that must be followed when installing, operating, and servicing the drive. Study this information carefully before working on or with the unit. Failure to follow these instructions may lead to personal injury or death or to damage to the drive, motor, or driven equipment.
Additional safety instructions specific to the application software can be found in the application documentation. Please study and follow those instructions as well.
Conventions Used
The following notation conventions are used throughout this manual to indicate information important to personal safety or machine hazards.
!
Attention
Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
ii 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
General Precautions
!
Attention
Only qualified personnel with the proper skills, instruction, and familiarity with the drive and its applications should install, start up, operate, troubleshoot, and maintain the drive. You must be familiar with the electrical and mechanical components of the system to perform the procedures outlined in this manual. Failure to comply may result in personal injury, death, and/or equipment damage.
!
Attention
Failure to take proper precautions for electrical hazard could cause injury or death.
!
Attention
Failure to follow industry safety standards and instructions in this manual could damage the drive and void the manufacturer’s warranty.
!
Attention
The drive may be sensitive to electrostatic discharge. Static precautions are required when servicing or repairing the unit.
!
Attention
If an aluminum electrolytic capacitor in the drive fails from a build-up of internal pressure, a safety vent will operate, spraying electrolyte vapor from the capacitor. If a capacitor vents, avoid contact with the liquid, avoid inhaling the vapors, and ventilate the area. If your skin comes in contact with the electrolyte, flush it immediately with cold water. If electrolyte gets in your eyes, immediately remove any contact lenses and flush the open eyes with plenty of clean water. If electrolyte is ingested, dilute it by drinking warm water and seek immediate medical attention.
!
Attention
Drives are intended for fixed, permanent connection to earthed three-phase supply mains. Use of EMC filters along with the equipment will increase leakage current in the protective conductor and may affect compatibility with residual-current-operated protective devices.
!
Attention
The drive provides solid-state motor overload protection. The level of protection is dependent upon the rating of the unit (given in Table 2-2) as well as the software overload specified by the user. Please refer to the application documentation for instructions on adjusting the overload.
Safety Information iii
Installation Precautions
!
Attention
An incorrectly installed or operated drive can result in damage to the equipment it controls. Make certain installation and operating specifications are followed.
!
Attention
To provide protection against electrical shock, drives must be mounted in an enclosure meeting at least the requirements of Protective Type IP20 (or NEMA equivalent) according to EN60529 and with top surfaces meeting at least the requirements of IP40 (or NEMA equivalent). It is recommended that a key or tool be required to open the enclosure and that enclosure doors be interlocked with the electrical supply disconnect.
!
Attention
The drive and associated equipment must be properly earth grounded.
!
Attention
Any site insulation tests must be performed before making electrical connections to the drive.
!
Attention
The drive is not equipped with a supply-disconnecting device. An external supply-disconnecting device must be provided to isolate incoming electrical supplies during installation and maintenance work. This device should comply with the requirements of EN 60204-1 as well as all applicable national and local regulations.
Application Precautions
!
Attention
Emergency stop devices shall be located at each operator control station and at other operating stations where emergency stop may be required. Control inputs and keypad motor-control functions do not generate an emergency stop of the motor and do not remove power that can cause hazardous conditions. Regardless of the operating state, the drive’s motor output terminals may be at dangerous voltage levels whenever input power is applied and the bus is charged.
iv 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
!
Attention
Drive functionality depends upon the application software installed. Some application software offers automatic restart functions that allow the unit to reset and resume operation after a fault. These functions must not be enabled when hazardous conditions might arise from such action. Certain features may present additional hazardous situations. Refer to the associated application documentation for further safety information.
Service Precautions
!
Attention
Always disconnect and lock out all electrical supplies before working on the drive or associated equipment. Do this before touching any electrical or mechanical components associated with the drive application.
!
Attention
High voltage may be present even when all electrical power supplies are disconnected. After switching off electrical power, wait at least 15 minutes for bus circuit capacitors to discharge before working on the drive or associated equipment. Use an appropriate voltmeter to further verify that capacitors are discharged before beginning work. Do not rely exclusively on the bus voltage indicator. Dangerous voltage levels may remain even when the indicator is off.
!
Attention
High voltage may be present at the motor output terminals (U, V, W) whenever input power is applied, regardless of whether the motor is moving or not.
!
Attention
Before energizing the motor, verify that there are no loose components associated with the drive train and that motor motion will not result in injury or damage to the equipment.
Safe Service Practices
Follow industry-recognized safety procedures:
• Use only one hand to hold test equipment probes
• Wear approved eye protection
• Stand on insulated material
• Use an isolated oscilloscope
• Keep unnecessary personnel out of the work area
• Never leave a drive cabinet open or unattended
About the Manual 1-1
1 About the Manual
1.1 Overview
This chapter describes the contents and intended audience of this document.
1.2 Contents
The manual provides the instructions and technical information necessary to install and maintain the hardware of Unico’s 1000 family of AC drives. Specifically, the manual pertains to units listed in Table 1-1. The 1140 Variable-Voltage AC Drive is covered separately in publication 1140.40 (111-564).
Table 1-1—1000 Family
Drive
Description
1100
Variable-Frequency AC Drive
1105
Variable-Frequency AC Drive
1110
Phase-Converting AC Drive
1120
Modular AC Drive
1130
Line-Regenerative AC Drive
1200
Variable-Frequency AC Drive
1230
Line-Regenerative AC Drive
What’s covered
Safety Instructions, discusses safety hazards and procedures important to anyone
working with the drive
• Chapter 2, Product Overview, tells how to receive the drive and provides an
overview of its architecture, features, and specifications
• Chapter 3, Mechanical Installation, provides instructions on physical installation
Chapter 4, Electrical Installation, explains the routine electrical connections
• Chapter 5, Troubleshooting/Maintenance, discusses troubleshooting and
maintenance of the drive hardware
What’s not covered
This manual does not address aspects of the drive that depend upon the application software. Please refer to the application documentation for the following:
• Application-specific control signal wiring and definitions
• Operator interface instructions
• Start-up procedure
• Detailed description of drive features and modes of operation
• Parameter descriptions
• Fault identification and troubleshooting
1-2 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
This manual is not intended to provide in-depth service instructions. For service beyond that described in this manual, please contact Unico or your representative.
1.2.1 Intended Audience
The manual is intended for anyone who will be installing and servicing the drive. Installation should be performed by qualified electrical personnel to ensure that correct electrical practices and applicable electrical codes are applied.
The audience is expected to have a basic knowledge of physical and electrical fundamentals, electrical wiring practices and components, and electrical schematics. No prior experience with the drive is presumed or required.
Follow instructions
You can prevent injury and damage to the drive or equipment by carefully following the procedures outlined in this manual.
Follow regulations
All electrical work should conform to the National Electrical Code as well as all state and local government regulations. Please familiarize yourself with these regulations.
Read both manuals first
Read this manual and the application manual entirely before installing the drive.
Product Overview 2-1
2 Product Overview
2.1 Overview
This chapter provides an overview of the 1000 family of drives. It gives instructions on unpacking, identifying, storing, and transporting a drive. It also familiarizes the user with the basic features, architecture, and specifications of the drives.
2.2 Unpacking
After opening the package, you should verify delivery and inspect the drive before installing, storing, or transporting the unit.
2.2.1 Lifting Instructions
Smaller drives are mounted on wooden supports and shipped in corrugated boxes, while the large drives are transported on skids. When unpacking a boxed drive, carefully follow the lifting instructions below.
!
Attention
The drive may weigh a considerable amount. To avoid the risk of personal injury and/or damage to the drive, two people should work in unison when lifting and maneuvering the unit. Follow industry prescribed safe-lifting practices at all times.
[1] Remove protective holder
Lift off the cardboard protector that holds the instruction manuals.
[2] Remove screws
Remove the four wood screws that secure the heat sink of the drive to the wooden shipping supports.
[3] Lift by the heat sink
Two people may be required to safely lift the drive from its box. Each person should stand at one end of the drive, facing the other. Using both hands, place your fingertips beneath the rim of the aluminum heat sink and lift carefully in unison.
!
Attention
To avoid damage, do not lift the drive by the keypad/display bracket or by the control modules.
2-2 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
2.2.2 Verify delivery
Check that you received the drive that was ordered as well as any options or accessories. Minimally, you should have received a drive and two manuals (this installation guide and an application guide). Contact your supplier regarding any discrepancies.
2.2.3 Inspect for damage
Inspect the drive for any damage that may have occurred during shipment. Remove the cover, if present, and visually examine the insides for obvious problems. If damage is found, do not operate the drive. Report the problem immediately to the supplier.
2.2.4 Storage/Transportation
If the drive must be stored or transported to another location before installation, verify that the ambient conditions are acceptable according to the environmental specifications given in Table 2-3. Choose a storage location that is clean, dry, and noncorrosive. Repack and store the drive in its original packaging.
2.2.5 Nameplate Identification
Drives are ordered using a model number similar to that shown in Figure 2-1. The model number identifies the drive type (1100, 1105, 1110, 1120, 1130, 1200, or 1230) and its configuration, including voltage, power, overload, control type, braking and packaging options, and application software. Each drive is labeled with an identification tag that indicates its part number, serial number, and input/output ratings.
Figure 2-1—Drive Model Number
Voltage Power Overload ControlBraking Package
001 002 003 005 007 010 015 020 025 030 040
050 060 075 100 125 150 200 250 300 350 400
500 600 800 10X
C = constant torque
(150% to 200% overload)
V = variable torque
(120% to 150% overload)
E = extended torque
(110% to 120% overload)
230 400 460 575
110 0 110 5 1110 112 0 113 0 1200 1230
N = w/o dynamic braking Y = w/dynamic braking R = regenerative braking
SoftwareModel
Without communication/memory option
0 = no optional interface (not available with 270 MHz) 1 = w/5 V incremental encoder 2 = w/5 V dual incremental encoder 3 = w/resolver with encoder emulation 4 = w/5 V encoder and resolver 5 = w/5 V triple incremental encoder 8 = w/5 V encoder and analog interface 9 = w/8-input/4-output analog interface
With communication/memory option
A = no optional interface (not available with 270 MHz) B = w/5 V incremental encoder C = w/5 V dual incremental encoder D = w/resolver with encoder emulation E = w/5 V encoder and resolver F = w/5 V triple incremental encoder G = w/5 V encoder and analog interface H = w/8-input/4-output analog interface
16 MHz Control
V0 = VFD control / 12-key interace
20 MHz Control
F0 = DCR control / 12-key interface F2 = DSV control / 12-key interface
40 MHz Control
S2 = 16-key interface
100 MHz Control
J2 = 16-key interface J5 = graphic display interface J7 = Bluetooth interface
270 MHz Control
K2 = 16-key interface K5 = graphic display interface K7 = Bluetooth interface
Compact 100 MHz Control
M2 = 16-key interface M5 = graphic display interface M7 = Bluetooth interface
Compact 150 MHz Control
N0 = 12-key interface N7 = Bluetooth interface
Open Chassis
C00 = flange-mounted C01 = foot-mounted
Basic Enclosure
E00 = flange-mounted E01 = foot-mounted E02 = flange-mounted prepunched E03 = foot-mounted prepunched
Packaged Drives
Pxx = package enclosure Dxx = operator desk Mxx = modified design
x00 = enclosure only x10 = w/option package 10 x11 = w/option package 11 x12 = w/option package 12 x13 = w/option package 13 x14 = w/option package 14 x20 = w/option package 20 x21 = w/option package 21 x22 = w/option package 22 x23 = w/option package 23 x24 = w/option package 24 x51 = w/option package 51
Product Overview 2-3
2.3 Family Overview
The 1000 family of AC drives provides digital flux vector control of ordinary three-phase AC motors. The drives combine the latest insulated-gate-bipolar-transistor (IGBT), pulse­width modulation (PWM), and digital signal processor (DSP) technologies with digital­current-regulator (DCR) or digital-space-vector (DSV) control to deliver optimum motor performance, complete programmability, and simplicity of operation. Variable-frequency drive (VFD) operation is also available for cost-effective control of motor speed in simple applications.
The complete family is comprised of the 1100, 1105, 1110, 1120, 1130, 1200, and 1230 series of variable-frequency drives as well as the 1140 variable-voltage drive. These drives share a common architecture that provides a high degree of internal consistency. By combining this core drive topology with unique input sections, the 1000 family furnishes flexible, efficient, and cost-effective solutions to a variety of application needs. Table 2-1 summarizes the various models within the family. The 1140 is described in a separate publication.
Table 2-1—1000 Family Summary
Drive
Description
Input Voltages
Power Range
Input Operation
1100
Variable-Frequency AC Drive
230/460/575 V
11/2-600 hp
Three- or six­phase rectifier
1105
Variable-Frequency AC Drive
230/460/575 V
11/2-300 hp
Three- or six­phase rectifier
1110
Phase-Converting AC Drive
230/460 V
11/2-100 hp
Single-phase rectifier
1120
Modular AC Drive
230/460 V
11/2-200 hp
Rectified DC bus
1130
Line-Regenerative AC Drive
230/460/575 V
71/2-150 hp
Three-phase rectifier/inverter
1140
Variable-Voltage AC Drive
230/460/575 V
5-500 hp
Three-phase SCR control
1200
Variable-Frequency AC Drive
230/460 V
11/2-1000 hp
Three- or six­phase rectifier
1230
Line-Regenerative AC Drive
460 V
11/2-600 hp
Three-phase rectifier/inverter
2.3.1 Features
Performance Flexibility
The 1000 family accommodates a broad range of performance requirements. Units may be configured for constant-torque operation for heavy-duty cyclic loads, variable-torque operation for medium-duty requirements, or extended-torque operation for centrifugal loads such as fans and pumps. The drive operates in a transducerless vector control mode that does not require a feedback device and produces full torque to base speed with full starting torque. For demanding applications, an incremental encoder or resolver interface can be added for precise position, velocity, and torque regulation and improved dynamic performance. Dual- and triple-encoder interfaces are also available for position-following and dual-transducer applications. Variable-frequency control is alternately available for applications that do not require critical velocity or torque control.
2-4 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Motor-Independent Design
The 1000 family drives operate any standard- or inverter-duty AC induction or synchronous motor, making it ideal for retrofits and new applications alike. A unique, proprietary digital current regulator (DCR) tunes the drive continuously in real time, eliminating the usual current-loop tuning process required by conventional drives. Digital space vector (DSV) control can be selected for reduced motor noise and low current ripple.
Auto Tuning
Once routine electrical connections have been made, simple-to-use auto-tuning features adjust virtually all motor- and load-dependent parameters. No motor maps are required. Simply enter basic motor information from the nameplate, and the advanced setup routines do the rest. The drive is completely tuned within minutes.
Control Options
Numerous control and interface options are available. The 16 MHz control module provides variable-frequency drive (VFD) control for simple applications. The 20 MHz and 40 MHz control modules are available in digital-current-regulator (DCR) and digital­space-vector (DSV) versions. The 100 MHz, 270 MHz, and Compact 100 MHz control modules provide for VFD, DCR, and DSV control. The Compact 150 MHz control module provides VFD and DSV control. Each control module provides digital and analog inputs and outputs as well as asynchronous serial communication capabilities. The 20 MHz, 40 MHz, 100 MHz, 270 MHz, and Compact 100 MHz modules also provide synchronous serial communication capabilities. The 100 MHz and 270 MHz modules include provision for an optional Anybus
®
module for communication using a variety of
industry-standard protocols, while the 100 MHz, 270 MHz, and the Compact 100 MHz modules include provision(s) for a MaxStream
module for wireless communication.
Depending upon the control module, drives can accept motor and/or machine feedback with a single, dual, or triple incremental encoder interface, a resolver interface, or resolver and encoder interfaces. An optional analog interface module is also available for expanding the analog I/O capabilities of a drive. One of three keypad/display units is available, depending upon the application.
Application Software
A wide variety of software options is available to tailor a drive to its application, from a fully featured velocity/torque control for general purposes to a host of powerful programs pre-engineered for specific applications. Customization is possible with many programs using UEdit™, a Windows-based programming tool that allows users extend an application using IEC 1131 standard ladder diagrams and function blocks.
Braking Options
The 1000 family offers both dynamic and regenerative braking options. A dynamic braking IGBT allows motor braking energy to be dissipated in an external resistor. This dynamic braking control is included as standard on all 1120 drives and smaller 1105 and 1200 drives. It is optional on larger 1105 and 1200 drives and all 1100 and 1110 drives. Appropriately sized external braking resistors are required. The 1130 and 1230 line­regenerative drives provide true four-quadrant control without requiring dynamic braking. Energy generated by stopping the motor and load is put back onto the power grid rather than wasted as heat in a resistor.
Product Overview 2-5
Digital Setup, Easy Operation
A keypad and liquid crystal display provide a simple interface for setting and viewing operating parameters and diagnostics. All controller settings are made digitally for precision and repeatability. Readouts and fault messages are displayed in readily understandable language. A graphical display option provides on-board oscilloscope-type viewing of drive and system parameters.
Multiaxis Operation
A built-in high-speed synchronous communication port allows the motion of multiple slave drives to be precisely coordinated. With optional master/slave software, the velocity ratio and position phasing of the drives can also be controlled. Multiple motors can be operated in parallel from a single drive using optional variable-frequency control.
Power Quality
A built-in link choke on the 1100, 1105, and 1110 drives and the unique low-capacitance design of the 1200 provides near-unity overall power factor and low harmonic line currents at all motor speeds. High-power 1100, 1105, and 1200 drives also offer a six­phase (twelve-pulse) configuration for further minimizing line harmonics in critical applications. The 1130 and 1230 line-regenerative drives provide near-unity power factor for both motoring- and braking-type loads by using an IGBT bridge to control the flow of power into and out of the drive.
Protection and Advanced Diagnostics
Drives monitor their operating conditions and provide a comprehensive set of overload, short circuit, and other electronic protective features to ensure safe, reliable operation. Faults indications are displayed in plain language. A log maintains a history of fault occurrences and externally triggered events.
Serial Connectivity
An RS-422/485 serial interface is provided for connecting a drive to a process controller, communication network, or programmable controller. A variety of popular communication protocols is available. The 100 MHz and 270 MHz modules also accept an Anybus® module with numerous industry-standard protocol options, and the 100 MHz, 270 MHz, and Compact 100 MHz modules accept MaxStream module(s) for wireless communications. An RS-232 connection is also provided on 40 MHz, 100 MHz, 270 MHz, Compact 100 MHz, and Compact 150 MHz controllers for connecting a personal computer. The Compact 150 MHz module also provides a USB 2.0 port for asynchronous communications. Windows-based PCs can set up, monitor, and control a network of drives using optional DriveLink™ or UEdit™ software. Drive Archive™ and Drive Chart™ for the Palm OS make it easy to save and restore setups and capture charts using a handheld computer.
Packaging
Compact and rugged, drives are available either enclosed or as an open chassis for mounting inside an enclosure. Both versions can be foot-mounted to a wall or subplate or flange-mounted through a cutout to dissipate heat outside an enclosure. Standard packaged systems are also available that incorporate additional components within an enclosure.
2-6 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
2.3.2 Drive Architecture
The general function of the drive is to convert a fixed voltage and frequency from an electrical power source into a variable voltage and frequency for controlling an AC motor. The basic architecture of the 1100, 1105, and 1110 drives is shown in Figure 2-2, that of the 1120 drive in Figure 2-3, that of the 1130 and 1230 drives in Figure 2-4, and that of the 1200 in Figure 2-5.
A rectifier section is used on the 1100, 1105, 1110, and 1200 drives to convert the fixed AC line voltage into a DC bus voltage. The 1120 is a modular design intended for operating a number of units from a common DC bus. Low-power drives use a diode rectifier and resistors to charge the bus capacitors, which is then bypassed by a contact once the bus is up to full voltage. Medium- and high-power drives use silicon-controlled rectifiers (SCRs) to control the charging of the bus capacitors. High-power drives provide for optional twelve-pulse (six-phase) connection of the input to reduce harmonic currents. The 1110 drive is designed for single-phase operation using two, rather than three, AC line voltage terminals. A rectifier control coordinates the charging of the bus.
A link choke and bus capacitors in the 1100, 1105, and 1110 drives form a filter that smoothes the output of the rectifier section into a steady DC voltage. An optional dynamic brake device on these units allows regenerative energy from the load to be dissipated in an external resistor when the drive is braking. The link choke and dynamic brake device are normally part of the converter supplying the DC bus to 1120 units.
A converter section is used on the 1130 and 1230 drives to regulate power flow between the AC line and DC bus. The converter uses an insulated gate bipolar transistor (IGBT) bridge to rectify the AC line voltage into a DC bus voltage. This section also regenerates energy from the DC bus to the AC line when the drive is braking.
An inverter section consisting of six insulated gate bipolar transistors (IGBTs) is used to power an AC motor. This section can produce sine-wave motor voltages and currents of any desired amplitude by rapidly switching the IGBTs using a technique called pulse­width modulation (PWM). A gate driver is used to pass switching signals from the drive controller to the IGBTs.
Overall operation of the unit is regulated by a drive control that incorporates a digital signal processor (DSP) and a digital current regulator (DCR) or digital space vector (DSV) control. This high-speed digital control uses both voltage and current feedback to regulate the output to the motor. Optional encoder and resolver interfaces are available to provide closed-loop control of motor velocity and/or position. A dual encoder option is available to slave the motor to other sections of a machine or to reduce machine resonance using dual transducer control. Variable-frequency drive (VFD) operation is an option for controlling AC motors in simple applications.
A keypad and display on the control module provide access to operating and setup parameters. The control module also provides analog and digital inputs that can be used as input to and output from the drive. Serial communication channels are also available for connecting drives to process controllers, communication networks, programmable controllers, or personal computers.
Product Overview 2-7
Figure 2-2—Architecture of the 1100, 1105, and 1110 Drives
Rectifier
Section
Rectifier
Control
Drive
Control
Serial
I/O
Analog
I/O
Digital
I/O
Gate
Driver
Transducer
Interface
Link
Choke
Dynamic
Brake
Inverter Section
AC
Motor
Optional
Transducers
Bus
Capacitors
AC
Line
Display
Keypad
Figure 2-3—Architecture of the 1120 Drive
Drive
Control
Serial
I/O
Analog
I/O
Digital
I/O
Gate
Driver
Transducer
Interface
Bus
Capacitors
Inverter Section
AC
Motor
Optional
Transducers
DC
Bus
Display
Keypad
Dynamic
Brake
2-8 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Figure 2-4—Architecture of the 1130 and 1230 Drives
Converter
Section
Converter
Control
Drive
Control
Serial
I/O
Analog
I/O
Digital
I/O
Gate
Driver
Transducer
Interface
Bus
Capacitors
Inverter Section
AC
Motor
Optional
Transducers
AC
Line
Display
Keypad
Figure 2-5—Architecture of the 1200 Drive
Rectifier
Section
Rectifier
Control
Drive
Control
Serial
I/O
Analog
I/O
Digital
I/O
Gate
Driver
Transducer
Interface
Dynamic
Brake
Inverter Section
AC
Motor
Optional
Transducers
Bus
Capacitors
AC
Line
Display
Keypad
Product Overview 2-9
2.4 Specifications
Detailed drive specifications are provided in Table 2-2 through Table 2-14 below.
Table 2-2—Electrical Specifications
Input Supply
Line voltage:
200 to 240 V AC, three phase (1100, 1105, 1120, 1130, and 1200) 220 to 240 V AC, single-phase (1110) 380 to 480 V AC, three-phase (1100, 1105, 1120, 1130, 1200, and 1230) 440 to 480 V AC, single-phase (1110) 500 to 600 V AC, three-phase (1100, 1105, and 1130)
Phase-sequence insensitive
Overvoltage Category III (IEC 664-1)
Voltage tolerance:
–10% of minimum, +10% of maximum
Imbalance:
Maximum ±3% of nominal input voltage
Frequency:
47 to 65 Hz
Short circuit rating:
85,000 Arms symmetrical
Power factor:
Displacement:
1.00 at all loads and speeds Overall:
0.99 at rated load (1230)
0.94 at rated load (1100, 1105, 1130, and 1200)
0.65 at rated load (1110)
Harmonic distortion:
(1230) Harmonics are below the limits defined in IEEE-519 for all I
SC/IL
. Each individual harmonic current fulfils IEE-519
table 10-3 for I
SC/IL
≥ 20. Current total harmonic distortion (THD) and each individual current harmonic fulfil IEC 61000­3-4 table 5.2 for R
SCE
66. The values will be met if the
supply network voltage is not distorted by other loads.
RSC
THD Voltage (%)
THD Current (%)
20 4 4
100
0.8
5
Output Rating
Voltage:
Zero to input supply voltage, three-phase (1100, 1105, 1120, 1130, 1200, and 1230) Zero to 90% of input supply voltage, three-phase (1110)
Frequency:
Zero to 120 Hz for transducerless vector control Zero to 180 Hz for transducer-based vector control Zero to 300 Hz for variable-frequency control
Switching frequency:
16 MHz control:
1.0, 1.9, 3.9, 7.8, and 15.6 kHz (see Table 2-14)
20 MHz control: Programmable from 1.1 to 6.5 kHz (see Table 2-14)
40 MHz, 100 MHz, 270 MHz, Compact 100 MHz, and Compact 150 MHz controls: Programmable from 1.0 to 12.0 kHz (see Table 2-14)
2-10 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Table 2-2—Electrical Specifications (continued)
Service Conditions
Efficiency:
97% nominal at rated switching frequency
Overload current
(†)
:
Torque
Overload (1 min)
Maximum
Constant
150% to 200% of rated
200% of rated
Variable
120% to 150% of rated
140% to 160% of rated
Extended (1100, 1105, 1120, 1130, 1200, 1230)
110% to 120% of rated
120% to 140% of rated
(†) Depending upon the application, the overload may reach the listed upper limit with a corresponding decrease in overload time. Refer to the application documentation for further information.
Table 2-3—Environmental Specifications
Operating Environment
Temperature:
Control section: 32° to 131° F (0° to 55° C) Heat sink (standard): 32° to 104° F (0° to 40° C) Heat sink (derated): 32° to 122° F (0° to 50° C)
Relative humidity:
5% to 95%, noncondensing
Altitude:
0 to 3,300 ft (0 to 1,000 m) above sea level
Derate output power 1% per 330 ft (100 m) above 3,300 ft (1,000 m).
Air pressure:
20.67" to 31.30" (70 to 106 kPa)
Vibration:
0.3 mm (2 to 9 Hz), 1 m/s2 (9 to 200 Hz) sinusoidal (IEC 68-2-6)
Pollution:
Nonconductive pollution according to Pollution Degree 2 of IEC 664-1
If the drive is to be used in a more polluted environment (Pollution Degree 3 or 4), suitable enclosures and air filtering or conditioning equipment must be used. To protect against dust ingress, an IP6x-rated enclosure (or NEMA equivalent) must be used.
Contamination levels:
Class 3C2 for chemicals (IEC 721-3-3) Class 3S2 for dust (IEC 721-3-3)
Storage Environment
Temperature:
–40° to 158° F (–40° to 70° C)
Relative humidity:
5% to 95%, noncondensing
Air pressure:
20.67" to 31.30" (70 to 106 kPa)
Transportation Environment
Temperature:
–40° to 158° F (–40° to 70° C)
Relative humidity:
5% to 95%, noncondensing
Air pressure:
20.67" to 31.30" (70 to 106 kPa)
Product Overview 2-11
Table 2-4—Performance Specifications
Frequency Control (16 MHz control)
Range:
Zero to base speed at full torque Base speed to 300 Hz at constant power
Resolution:
0.024% with analog input (12-bit)
0.1 Hz with digital input
Velocity Control (20, 40, 100, 270 MHz, Compact 100 MHz, and 150 MHz control)
Range:
Zero to base speed at full torque Base speed to 180 Hz at constant power with transducer Base speed to 120 Hz at constant power without transducer
Regulation:
±0.001% of base speed, down to zero, with transducer ±0.5% of base speed, 2 Hz and above, without transducer
Torque Control (20, 40, 100, 270 MHz, Compact 100 MHz, and Compact 150 MHz control)
Starting torque:
Constant torque: zero to 150% to 200% of rated Variable torque: zero to 120% to 150% of rated Extended torque: zero to 110% to 120% of rated (1100, 1105, 1120, 1130, 1200, and 1230)
Regulation:
±2.0% of maximum with transducer ±5.0% of maximum without transducer
2-12 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Table 2-5—Processor/Memory Specifications
Central processing unit:
16 MHz control: 80C196 microprocessor
20 and 40 MHz controls: 56002 digital signal processor (DSP)
100 MHz amd Compact 100 MHz controls: 56309 digital signal processor (DSP)
270 MHz control: 56321 digital signal processor (DSP)
Compact 150 MHz control: TMS320F2812 digital signal processor (DSP)
Clock frequency:
16 MHz, 20 MHz, 40 MHz, 100 MHz, 150 MHz, or 270 MHz
Data memory:
16 MHz control: 2 kilobyte battery-backed static RAM
20 MHz control: 16 kilobyte battery-backed static RAM
40 MHz control: 32 kilobyte battery-backed static RAM
100 MHz and Compact 100 MHz controls: 128 kilobyte battery-backed static RAM
270 MHz control: 512 kilobyte battery-backed static RAM
Compact 150 MHz control: 128 kilobyte battery-backed static RAM
Memory expansion module: Accepts SD flash memory card up to 2 GB
Scratch pad memory:
16 MHz control: 256 byte high-speed RAM
20 MHz control: 24 kilobyte high-speed RAM
40 MHz control: 142 kilobyte high-speed RAM
100 MHz, 270 MHz, and Compact 100 MHz controls:
1.5 megabyte high-speed RAM
Compact 150 MHz control: 36 kilobyte high-speed RAM
Program memory:
16 MHz control: 64 kilobyte flash EPROM
20 MHz control: 384 kilobyte flash EPROM
40 MHz control:
1.5 megabyte flash EPROM
100 MHz and Compact 100 MHz controls:
3.0 megabyte flash EPROM
270 MHz control:
6.0 megabyte flash EPROM
Compact 150 MHz control: 256 kilobyte flash EPROM
Product Overview 2-13
Table 2-6—Input/Output Specifications
Analog
Inputs:
16 MHz and 20 MHz controls: Three (3) 12-bit analog inputs (±10 V DC, 0 to 10 V DC, and 0 to 20 mA)
40 MHz, 100 MHz, 270 MHz, Compact 100 MHz, and Compact 150 MHz controls: Three (3) 12-bit analog inputs (±10 V DC or 0 to 20 mA)
Analog Interface Module (optional): Eight (8) 12-bit analog inputs (0 to 10 V DC or 0 to 20 mA)
Outputs:
16 MHz and 20 MHz controls: Two (2) 12-bit analog outputs (±10 V DC)
40 MHz, 100 MHz, 270 MHz, and Compact 100 MHz controls: Two (2) 12-bit analog outputs (±10 V DC and 0 to 20 mA)
Compact 150 MHz control: Two (2) 10-bit analog outputs (±10 V DC and 0 to 20 mA)
Analog Interface Module (optional): Four (4) 12-bit analog outputs (±10 V DC)
Digital
Inputs:
16 MHz, 40 MHz, 100 MHz, 270 MHz, Compact 100 MHz, and Compact 150 MHz controls: Twelve (12) digital inputs (require sink of 1 mA to common)
20 MHz control: Eleven (11) digital inputs (require sink of 1 mA to common)
I/O Fanning Strip (optional): Provision for input converters rated 2.5 to 2.8 V DC @ 30 mA, 90 to 140 V AC @ 11 mA, and 180 to 270 V AC @ 5 mA
Outputs:
16 MHz and 20 MHz mixed I/O controls: Three (3) digital outputs (Form C contacts rated 125 V AC @ 5 A, Form A contact rated 125 V AC @ 5 A, and open-collector driver rated 24 V DC @ 500 mA)
40 MHz, 100 MHz, 270 MHz, Compact 100 MHz, and Compact 150 MHz logic I/O controls: Six (6) digital outputs (open-collector driver rated 24 V DC @ 500 mA)
I/O Fanning Strip (optional): Provision for output converters rated 5 to 60 V DC @ 3 A, 12 to 140 V AC @ 3 A, or 24 to 270 V AC @ 3 A; or for normally-open or normally-closed relay converters rated 250 V AC @ 8 A
2-14 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Table 2-7—Serial Communication Specifications
Asynchronous
Port(s):
16 MHz and 20 MHz controls: RS-422/485, isolated
40 MHz control: RS-232/422/485, isolated Auxiliary RS-422/485
100 MHz and 270 MHz controls: RS-232/422/485 Two (2) auxiliary RS-422/485
Compact 100 MHz control: RS-232/422/485 Auxiliary RS-422/485
Compact 150 MHz control: RS-232/422/485 USB 2.0
Baud rate:
Application dependent
Protocol:
Application dependent
Synchronous
Port:
20 MHz, 40 MHz, 100 MHz, 270 MHz, and Compact 100 MHz controls: RS-485 for high-speed master/slave networking
Table 2-8—Communication Module Specifications
Interfaces:
100 MHz control: One (1) Anybus® communication provision One (1) Bluetooth® or MaxStream™ wireless communication provisions
270 MHz control: One (1) Anybus® communication provision Two (2) Bluetooth® or MaxStream™ wireless communication provisions
Compact 100 MHz and Compact 150 MHz controls: One (1) Bluetooth® or MaxStream™ wireless communication provision
Anybus® options:
Anybus® CANopen communication module Anybus® CC-Link® communication module Anybus® ControlNet™ communication module Anybus® DeviceNet™ communication module Anybus® Ethernet communication module Anybus® Interbus communication module Anybus® LonWorks® communication module Anybus® Modbus® Plus communication module Anybus® Profibus DPV1 communication module Anybus® Profibus Master communication module
MaxStream™ options:
MaxStream™ 900 MHz wireless communication module
MaxStream™ 2.4 GHz wireless communication module
Product Overview 2-15
Table 2-9—Encoder Interface Specifications
Internal supply:
5 V DC @ 250 mA
Channels:
100 MHz (323-397 and 323-547), 270 MHz, Compact 100 MHz (323-060), and Compact 150 MHz Control Modules: A, B, marker, reference
Encoder Interface Module: A, B, marker
Dual Encoder Interface Module: A, B, marker, reference
Allowable quadrature error:
±36°
Maximum input frequency:
250 kHz
Switching threshold:
200 mV
Input Impedance:
120 Ω
Differential input voltage:
±5 V
Common mode input voltage:
±5 V
Table 2-10—Resolver Interface Module with Encoder Emulation Specifications
Reference Output
Frequency:
5 kHz
Amplitude:
4 V
rms
Feedback Input
Sine/cosine amplitude:
2 V
rms
Transformation ratio:
0.5
Resolution
10- to 16-bit, programmable
Maximum Recommended Speed
Resolution
Speed
10-bit
50,000 rpm
12-bit
12,000 rpm
14-bit
3,000 rpm
16-bit
800 rpm
Encoder Emulation
Channels:
A, B, marker, feedback error
Resolution:
Resolver Resolution
Quadrature Output
10-bit
256 ppr
12-bit
1,024 ppr
14-bit
4,096 ppr
16-bit
16,384 ppr
2-16 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Table 2-11—Protection Specifications
• Ground fault
• Motor phase-to-phase short circuit
• DC bus overvoltage
• DC bus undervoltage
• Instantaneous overcurrent
• Motor overload
• Heat sink overtemperature
• Ambient overtemperature
• Power transistor fault (except 16 MHz control)
• Logic power undervoltage (except 16 MHz control)
• Memory malfunction
• Processor not running fault (except 16 MHz control)
Refer to the application documentation for additional protective features.
Product Overview 2-17
Table 2-12—Product Range
Input Voltage
Application
Constant-Torque
Variable-Torque
Extended-Torque
1100
230 V AC
11/2-60 hp
2-75 hp
(1.1-45 kW)
(1.5-55 kW)
380 V AC
11/2-350 hp
2-400 hp
(1.1-262 kW)
(1.5-300 kW)
460 V AC
11/2-350 hp
2-400 hp
25-500 hp
(1.1-262 kW)
(1.5-300 kW)
(18-375 kW)
575 V AC
11/2-400 hp
2-500 hp
40-600 hp
(1.1-300 kW)
(1.5-375 kW)
(30-450 kW)
1105
230 V AC
11/2-20 hp
2-25 hp
(1.1-15 kW)
(1.5-18 kW)
380 V AC
11/2-150 hp
2-200 hp
(1.1-110 kW)
(1.5-150 kW)
460 V AC
11/2-150 hp
2-200 hp
10-250 hp
(1.1-110 kW)
(1.5-150 kW)
(7.5-185 kW)
575 V AC
11/2-200 hp
2-250 hp
10-300 hp
(1.1-150 kW)
(1.5-185 kW)
(7.5-225 kW)
1110
230 V AC
11/2-40 hp
2-50 hp
(1.1-30 kW)
(1.5-37 kW)
460 V AC
11/2-75 hp
2-100 hp
(1.1-55 kW)
(1.5-75 kW)
1120
230 V AC
11/2-60 hp
2-75 hp
10-100 hp
(1.1-45 kW)
(1.5-55 kW)
(7.5-75 kW)
460 V AC
11/2-125 hp
2-150 hp
10-200 hp
(1.1-90 kW)
(1.5-110 kW)
(7.5-150 kW)
1130
230 V AC
71/2-60 hp
10-75 hp
(5.5-45 kW)
(7.5-55 kW)
380 V AC
71/2-125 hp
10-150 hp
(5.5-90 kW)
(7.5-110 kW)
460 V AC
71/2-125 hp
10-150 hp
25-150 hp
(5.5-90 kW)
(7.5-110 kW)
(18-110 kW)
575 V AC
71/2-125 hp
10-150 hp
25-150 hp
(5.5-90 kW)
(7.5-110 kW)
(18-110 kW)
1200
230 V AC
11/2-20 hp
2-25 hp
10-30 hp
(1.1-15 kW)
(1.5-18 kW)
(7.5-22 kW)
380 V AC
11/2-600 hp
2-800 hp
(1.1-450 kW)
(1.5-600 kW)
460 V AC
11/2-600 hp
2-800 hp
10-1000 hp
(1.1-450 kW)
(1.5-600 kW)
(7.5-750 kW)
1230
460 V AC
11/2-400 hp
2-500 hp
20-600 hp
(1.1-300 kW)
(1.5-375 kW)
(15-450 kW)
2-18 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Table 2-13—Output Current Ratings
Power
Current
Constant Torque
Variable Torque
Extended Torque
Continuous
Overload
Maximum
Overload
Maximum
Overload
Maximum
hp (kW)
A
rms
A
rms
A
rms
A
rms
A
rms
A
rms
A
rms
230 V
11/2
6.0
9.0
12.0 — — — —
(1.1)
2
6.8
10.2
13.6
8.2
12.0 — —
(1.5)
3
9.6
14.4
19.2
11.5
13.6 — —
(2.2)
5
15.2
22.8
30.4
18.2
19.2 — —
(3.7)
71/2
22.0
33.0
44.0
26.4
30.4 — —
(5.5)
10
28.0
42.0
56.0
33.6
44.0
30.4
30.4
(7.5)
15
42.0
63.0
84.0
50.4
56.0
44.0
44.0
(11)
20
54.0
81.0
108.0
64.8
84.0
56.0
56.0
(15)
25
68.0
102.0
136.0
81.6
108.0
74.8
84.0
(18)
30
80.0
120.0
160.0
96.0
136.0
88.0
108.0
(22)
40
104.0
156.0
208.0
124.8
160.0
114.4
136.0
(30)
50
130.0
195.0
260.0
156.0
208.0
143.0
160.0
(37)
60
154.0
231.0
308.0
184.8
260.0
169.4
208.0
(45)
75
192.0
— — 230.4
308.0
211.2
260.0
(55)
100
248.0
— — — — 272.8
308.0
(75)
(continued)
The ratings provided in this table reflect standard overloads of 150% (CT), 120% (VT), and 110% (ET). Depending upon the application software, units may be operated at up to 200% (CT), 150% (VT), and 120% (ET) overload. To determine the maximum overload current for alternate VT and ET ratings, use the CT overload for the same power rating but limit it to the VT or ET maximum current. Refer to the application documentation for further information.
Product Overview 2-19
Table 2-13—Output Current Ratings (continued)
Power
Current
Constant Torque
Variable Torque
Continuous
Overload
Maximum
Overload
Maximum
hp (kW)
A
rms
A
rms
A
rms
A
rms
A
rms
380 V
11/2
3.5
5.2
6.0 — —
(1.1)
2
3.9
5.9
6.8
4.7
6.0
(1.5)
3
5.5
8.3
9.6
6.6
6.8
(2.2)
5
8.7
13.1
15.2
9.6
9.6
(3.7)
71/2
12.7
19.0
22.0
15.2
15.2
(5.5)
10
16.1
24.2
28.0
19.3
22.0
(7.5)
15
24.2
36.2
42.0
28.0
28.0
(11)
20
31.1
46.6
54.0
37.3
42.0
(15)
25
39.1
58.7
68.0
46.9
54.0
(18)
30
46.0
69.0
80.0
55.2
68.0
(22)
40
59.8
89.7
104.0
71.8
80.0
(30)
50
74.8
112.1
130.0
89.7
104.0
(37)
60
88.6
132.8
154.0
106.3
130.0
(45)
75
110.4
165.6
192.0
132.5
154.0
(55)
100
142.6
213.9
248.0
171.1
192.0
(75)
125
179.4
269.1
312.0
215.3
248.0
(90)
150
207.0
310.5
360.0
248.4
312.0
(110)
200
276.0
414.0
480.0
331.2
360.0
(150)
(continued)
2-20 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
Table 2-13—Output Current Ratings (continued)
Power
Current
Constant Torque
Variable Torque
Continuous
Overload
Maximum
Overload
Maximum
hp (kW)
A
rms
A
rms
A
rms
A
rms
A
rms
380 V
1100:
250
345.0
517.5
600.0
414.0
480.0
(185)
300
414.0
621.0
720.0
496.8
600.0
(225)
350
483.0
724.5
840.0
579.6
720.0
(262)
400
552.0
— — 662.4
840.0
(300)
1200:
250
345.0
517.5
600.0
414.0
480.0
(185)
300
414.0
621.0
720.0
496.8
600.0
(225)
400
552.0
828.0
960.0
662.4
720.0
(300)
500
690.0
1035.0
1200.0
828.0
960.0
(375)
600
828.0
1242.0
1440.0
993.6
1200.0
(450)
800
1104.0
— — 1324.8
1440.0
(600)
(continued)
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