Related Manuals for Control Techniques Unidrive Regen
Summary of Contents for Control Techniques Unidrive Regen
- Page 1 www.controltechniques.com Installation Guide Unidrive Regen Part Number: 0460-0026-02 Issue Number: 2...
- Page 2 This product is supplied with the latest version of software. If this product is to be used in a new or existing system with other drives, there may be some differences between their software and the software in this product. These differences may cause this product to function differently. This may also apply to drives returned from a Control Techniques Service Centre.
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Page 3: Table Of Contents
Varistors ...............................13 Fusing ..............................14 Important considerations....................16 Fundamentals ............................16 Unidrive size 3 and 4 ...........................16 Ventilation ............................16 Cable length restrictions ........................17 Unidrive Regen EMC information................19 Immunity ..............................19 Emission ..............................19 Dedicated supplies ..........................19 Other supplies ............................19 Supply voltage notching ........................19 Supply harmonics ..........................19 Switching frequency emission ......................19... - Page 4 Appendix A Unidrive Regen as a Brake Resistor Replacement ..........30 Introduction ............................30 Drive configurations ..........................30 When to use a Regen drive as a brake resistor replacement ............. 30 Regen and motoring drive ratings ....................... 31 Power circuit connections and components ..................31 Control circuit connections ........................
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Page 5: Introduction
Figure 1-2 Phasor diagram Power flow from supply Power flow back to supply Supply Voltage Voltage at line terminals of Regen drive jωLI Voltage across Regen Inductor Current at line terminals of Regen drive Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... -
Page 6: Power Flow
• Under conditions of AC mains instability, a Unidrive Regen system can continue to function down to approximately 150Vac supply voltage without any effect on the DC bus voltage and hence on the operation of the motoring drives (increased current will be taken from the AC supply to compensate up to the current limit of the Regen drive) •... -
Page 7: Sizing Of A Regen System
Regen drive. NOTE If the system consists of one Regen Unidrive and more than three motoring drives, Control Techniques Technical Support MUST be consulted about the design of the system. -
Page 8: Power Connections
Power connections The following section covers the power connections required for Unidrive Regen systems. Note that with Unidrive Regen systems there are no AC supply connections made to L1, L2 or L3 drive terminals. NOTE For control circuit connections refer to Chapter 4 Control circuit connections on page 8. - Page 9 3.1.1 Standard single Regen, single/multiple motoring system Figure 3-1 Power connections: Single Regen Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
- Page 10 High power set-ups should use Unidrive size 5. This is the only module which is designed for parallel Regen operation. For systems with more than two Unidrive size 5 drives in parallel Regen operation, contact CT Technical Support. Figure 3-2 Power connections: Unidrive size 5 multiple Regen Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 11: Non Standard Configurations
Non standard configurations There are a number of possible options available when designing a Unidrive Regen system depending on the user requirements and the nature of the AC supply. Non standard systems can be created where favourable supply conditions exist, allowing cost and space savings to be achieved by reducing the number of components. -
Page 12: Control Circuit Connections
NOTE Unidrive Regen has been designed to operate in negative logic as default. In order for the drive to be configured to operate in positive logic alterations must be made to the control connections and parameter settings (contact C.T. Technical Support for this information). -
Page 13: Regen Inductor Thermistors
+24V Out 0V Digital At Zero Speed O/P Digital I/O 1 Reset Digital I/O 2 Digital I/O 3 Digital I/P 1 Digital I/P 2 Digital I/P 3 Enable User enable 0V Digital Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... -
Page 14: Components
Components The following parts are required to assemble a Unidrive Regen system: • Motoring drive • Regen drive • Regen inductor • Softstart resistor • Contactors, MCBs and overload • Switching frequency filter (optional) • RFI filter (optional) • Varistors •... -
Page 15: Softstart Resistor
Regen and motoring drive is connected through. This will act as a safe guard and prevent the system running with a fault on the switching frequency filter. Also refer to Appendix B Component sizing calculations on page 36. Unidrive Regen Installation Guide Issue Number: 2... -
Page 16: Switching Frequency Filter
An MCB should be fitted between the AC supply and the capacitor. This is to protect the wiring between the capacitor and the main bus bar. NOTE For multiple Regen systems, refer to Appendix B Component sizing calculations on page 36 for sizing of the MCB. Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... -
Page 17: Rfi Filter
AC line voltage transients can typically be caused by the switching of large items of plant, or by lightning strikes on another part of the supply system. If these transients are not suppressed, they can cause damage to the insulation of the Regen input inductors, or to the Unidrive Regen drive electronics. -
Page 18: Fusing
Figure 5-3 Fusing: Multiple size 1 to 4 motoring drives Regen system Motoring Drive Main Regen Supply Contactor Inductor Regen Fusing Drive 3 Phase Additional DC Bus Supply Circuitry Fusing Motoring Drive Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... - Page 19 Regen Output Inductor Sharing Regen Motoring Drive Drive Choke Main Supply Contactor Fusing Regen 3 Phase Additional DC Bus Circuitry Supply Fusing Fusing Regen Motoring Drive Drive Output Regen Sharing Inductor Choke Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
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Page 20: Important Considerations
When sizing the cubicle(s) for the Regen system considerations must be made for the systems losses. System Losses Documented In... RFI Filter Regen drive Motoring drive Unidrive Size 1 to 5 User Guide Control Module, Unidrive size 5 Power Module, Unidrive size 5 Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... -
Page 21: Cable Length Restrictions
The DC power output from the Unidrive which is used as the input stage to the motoring drive(s) carries a common-mode high frequency voltage comparable with the output voltage from a standard drive. All precautions recommended for motor cables must also be applied to all cables connected to this DC circuit. Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... - Page 22 15 - 37 45 - 110 200 per Regen drive If the cable length in the above table is exceeded, additional components are required. Refer to Appendix C Long cables on page 41. Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 23: Unidrive Regen Emc Information
Unidrive Regen EMC information Immunity The immunity of the individual drive modules is not affected by operation in the regenerative mode. See drive EMC data sheets for further information. This Guide recommends the use of varistors between the incoming AC supply lines. These are strongly recommended to protect the drive from surges caused by lightning activity and/or mains supply switching operations. - Page 24 Table 7-3 Conducted emission from 150kHz to 30MHz Generic standard Product standard EN55011 Class A Group 1 Industrial, scientific and medical EN50081-2 CISPR 11 Class A Group 1 equipment EN55022 Class A Information technology CISPR 22 Class A equipment Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 25: Radiated Emission
For current up to 300A the Control Techniques filters listed previously are suitable. For currents exceeding 300A up to 2400A suitable filters are available from the following manufacturers: Siemens B84143.A250.S (range up to 2500A) -
Page 26: Parameter Descriptions
When the sinusoidal rectifier unit is active this parameter gives the supply frequency. Positive values indicate positive phase sequence and negative values indicate negative phase sequence. If the unit is not active this parameter shows zero. Unidrive Regen Installation Guide www.controltechniques.com... - Page 27 Setting this parameter to 1 modifies the IGBT switching pattern so as to reduce the number of switching events. This has the following effects: • Slightly reduced power loss in the Regen drive. • Increased acoustic noise from input inductors. Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
- Page 28 0. This bit should be routed to a digital output and used to enable the motoring drive(s) connected to the DC bus of the Regen drive. Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
- Page 29 Regen drive. If the power flow from the supply is increased (i.e. more power is taken from the supply or less power is fed back into the supply) the DC bus voltage will fall, but the minimum level will be limited to just below the peak rectified level of the supply provided the maximum rating of the Unidrive Regen Installation Guide Issue Number: 2...
- Page 30 Therefore the gain may be changed when the DC bus capacitance is not equal to twice the Regen drive capacitance. However, care must be taken to ensure that the gain is not too high as this can cause excessive ripple in the DC bus voltage. Unidrive Regen Installation Guide www.controltechniques.com...
- Page 31 Power calculations Supply 15.03 V x I x 3 power Input Read-write (RW) 0.XX terminals parameter Read-only (RO) Output 0.XX parameter terminals The parameters are all shown at their default settings Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
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Page 32: Commissioning And Operation
Regen drive is disabled the MCB trips then: • the Regen drive will inhibit • the motoring drive will be disabled by the Regen drive the DC bus voltage will fall to √2 Vac • Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... -
Page 33: Regen Drive Commissioning
Drive Enabled but AC voltage too low, or DC bus voltage still rising, or DC bus STOP voltage still falling. Waiting for correct conditions to synchronise onto line SCAN Drive enabled and synchronising to line Drive enabled, synchronised and active Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... -
Page 34: Appendix A Unidrive Regen As A Brake Resistor Replacement
Appendix A Unidrive Regen as a Brake Resistor Replacement Introduction The Regen drive has been designed to provide a regulated DC supply to other motoring drives. The Regen drive gives bi-directional power flow with sinusoidal currents and a near unity. -
Page 35: Regen And Motoring Drive Ratings
Switching frequency filter MCB auxiliary through which Regen drive enable is aux1x connected aux2 Main contactor auxiliary for “main contactor closed signal” aux3 K3 auxiliary with coil supply for K2 Ovld Thermal, Magnetic overload Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... - Page 36 Figure A-2 Power connections: Single Regen Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
- Page 37 Regen drive with the current rating equal to the Regen drive continuous current rating. The transformer leakage inductance forms the switching frequency filter inductance. The inductance value for the switching frequency filter is specified in Chapter 5 Components on page 10. NOTE A non isolating transformer cannot be used under any circumstances. Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
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Page 38: Control Circuit Connections
+24V Out 0V Digital At Zero Speed O/P Digital I/O 1 Reset Digital I/O 2 Digital I/O 3 Digital I/P 1 Digital I/P 2 Digital I/P 3 Enable User enable 0V Digital Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... -
Page 39: Regen Brake Drives In Operation
With a larger difference between the peak AC supply voltage and the DC bus voltage set point there is more energy storage available for transient peaks in the braking power. Table A-3 gives recommended DC bus voltage set points. Table A-3 DC bus voltage set points - Pr 15.07 (Pr 0.17) Supply Voltage Recommended Maximum Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... -
Page 40: Appendix B Component Sizing Calculations
3 pole with auxiliary (for enable) Table B-1 Power rating Total DC bus capacitance Drive size (kW) (µF) 11.0 15.0 1,100 18.5 1,100 22.0 2,200 30.0 2,200 37.0 2,200 3,300 3,300 4,400 6,600 6,600 8,800 Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... -
Page 41: Resistor Sizing For Multiple Motoring Systems
4. Total rms current needed = 0.6 + (3 x 0.5) + (5 x 0.4) = 4.1A 5. Power loss in 16Ω bank (85W per resistor) = 256W, resistor bank maximum rating = 3 x 148W = 444W, so the 16Ω resistor arrangement is suitable. Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... -
Page 42: Multiple Unidrive Size 5 Systems
Figure B-2 on page 39. The peak current and charge time during power up can be calculated using the following formula. Unidrive Regen Installation Guide www.controltechniques.com... - Page 43 Peak current at power up = 528Vac / 24Ω = 22A Thermal / Magnetic overload current rating = 22A / 20 = 1.1A (use 1.6A) 10 x nominal power = 2.960kW Current flowing during overload √2960 / 24 = 11.01A Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
- Page 44 Figure B-1 it can be seen that for a current of 11.10A when using a 1.6A breaker that the overload will trip at 7 x the nominal current (11.10/1.6 = 6.9), which equates to approximately 5 seconds trip level worst case. Figure B-3 Example of overload characteristic 50 100 0 1 2 Duration of Load (seconds) Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 45: Appendix C Long Cables
RFI filter. To prevent this, some capacitance line to ground should be provided as an additional path for this current, as shown in Figure C-1. NOTE If the maximum cable length exceeds the maximum cable length with additional cooling, Control Techniques Technical Support must be consulted. Figure C-1 Unidrive Regen layout... - Page 46 Typically values of about 5MΩ are suitable, and are high enough not to cause the system to fail a simple insulation test. WARNING Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 47: Appendix D Regen Kits
Appendix D Regen kits Single Regen, single motoring systems Standard kits of Regen components for Unidrive Regen systems which consist of a single Regen drive and a single motoring drive. Refer to Table D- 1 for details. Table D-1 Standard kits... -
Page 48: Appendix E Unidrive Regen Specifications
135A 105A UNI 4404 90kW 180A 150A 125A UNI 4405 110kW 190A 150A 125A UNI 5401 240A* 150% *No UL approval for Unidrive size 5 with 240A continuous in a 50°C ambient. Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... -
Page 49: Appendix F Physical Dimensions
6 way terminal block APPX WEIGHT: 12kg for lead termination. SKOT TRANSFORMER LTD. (mk6) COPYRIGHT 2 way terminal block for thermister termination (mk3) 4 OFF 9 FIXING HOLE 140 fixing centres 120 fixing centres Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... - Page 50 Figure F-2 Type 2 dimensions PROJECTION 11 HOLE SKOT TRANSFO RME R LTD. COPYRIGHT 4 OFF 11 FIXING HOLE Figure F-3 Type 3 dimensions SKOT TRANSFORMER LT COPYRIGHT 11 HOLE 4 OFF HOLES Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 51: Softstart Resistor - Type Tg Series
22.2 165.1 1270-2483 4 & 5 48Ω x 2 22.2 165.1 1270-2483 Figure F-5 Resistor mounting bracket dimensions Table F-3 Resistor mounting bracket dimensions Mounting bracket dimensions 21.45mm ±0.2 ∅5.0 24.0mm 33.5mm Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... -
Page 52: Switching Frequency Filter Capacitors
Fast-on terminal (6.35mm) Internal connection ØD Table F-4 Specifications ∅ x L Weight Drive size Mounting CT part number (µF) (mm) (kgs) 1 & 2 3 x 5.7 53 x 116 M8 Stud 1610-5752 Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2... - Page 53 CT part number (µF) (mm) (kgs) 3 x 24 121 x 164 M12 Stud 1665-2244 3 x 48 121 x 164 M12 Stud 1665-2484 3 x 80 142 x 200 M12 Stud 1665-2804 Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com...
- Page 54 Figure F-8. For Unidrive size 1 and 2 the discharge resistors are fitted internally to the capacitor. Figure F-8 Discharge resistor arrangement Table F-6 Specifications Drive size Capacitor value Resistor value 1 & 2 5.7µF Internal 24µF 3 x 390kΩ 48µF 3 x 390kΩ 80µF 3 x 270kΩ Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 55: Switching Frequency Filter Inductor
0.025 4401-0179 Figure F-9 Switching frequency filter inductor (Type 1) 4 OFF SL 8mm WID Figure F-10 Switching frequency filter inductor (Type 2) 9 HOLE APPX WEIGHT: 25kg 4 off sl 10mm Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... - Page 56 Figure F-11 Switching frequency filter inductor (Type 3) 4 OFF S 10mm W Figure F-12 Switching frequency filter inductor (Type 4) 4 OFF 14 HOLES IN EACH FLAG 4 OFF 11 FIXING HOLE 320 fixing centres 240 fixing centres Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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Page 57: Varistors
Varistors Figure F-13 Dimensions 1 Nom 60 max 8 dia. hole 25° Table F-8 Specification Voltage Energy Drive size CT part number 1 to 5 2482-1501 1 to 5 2482-0680 Unidrive Regen Installation Guide Issue Number: 2 www.controltechniques.com... - Page 58 Isolating transformer ............... 33 Wiring guidelines ..............21 Kits ..................43 Line to ground capacitors ............41 Logic diagram ................. 27 Long cables ................41 Magnetic overload ..............38 Magnetic overload sizing ............38 Unidrive Regen Installation Guide www.controltechniques.com Issue Number: 2...
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