Nidec Answer Drives 1000 User And Maintenance Manual
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Nidec Answer Drives 1000 User And Maintenance Manual

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  • Page 1 AD1000 User and Maintenance Manual...
  • Page 2 NIDEC ASI S.p.A. – USER AND MAINTENANCE MANUAL IMAD10002EN – Rev. 01 – 1st June 2016...
  • Page 3 Answer Drives 1000 Voltage Source Drive User and Maintenance Manual Code: IMAD10002EN Revision: Rev. 01 Date: 1st June 2016 Language: English Translation of the Original Instructions NIDEC ASI S.p.A. – USER AND MAINTENANCE MANUAL IMAD10002EN – Rev. 01 – 1st June 2016...
  • Page 4 DOCUMENT REVISIONS Revision Date Notes 30th July 2015 First issue 1st June 2016 General update For further information, go to: nidec-answerdrives.com NIDEC ASI S.p.A. – USER AND MAINTENANCE MANUAL IMAD10002EN – Rev. 01 – 1st June 2016...

  • Page 5: Table Of Contents

    Applied directives and declaration of incorporation ........................55 4.3.6 Intended use and limits of use ..............................56 4.3.7 Danger zones ....................................56 Environmental working conditions ................................58 4.4.1 Vibrations ..................................... 58 Environmental storage conditions ................................59 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 6 External power supply to the control ..............................127 PREVENTIVE MAINTENANCE ................................... 129 AD1000 – PM001 Drive ..................................130 AD1000 – PM002 Drive ..................................131 AD1000 – PM003 Drive ..................................132 AD1000 – PM004 Drive ..................................133 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 7 AD1000 SUMMARY AD1000 – PM005 Drive ..................................134 AD1000 – PM006 Drive ..................................135 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 8 SUMMARY AD1000 This page is intentionally left blank. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 9: Manufacturer

    AD1000 INTRODUCTION MANUFACTURER ANSWER DRIVES 1000 was built at the Nidec ASI S.p.A. plant in Montebello (VI) - Italy MANUFACTURER’S ADDRESS For any type of information regarding use, maintenance, installation, customer assistance at the customer’s premises, ordering spare parts, etc. contact the closest Nidec customer assistance centre.

  • Page 10: User And Maintenance Manual

    HAZARD Answer Drives 1000 is designed to be incorporated into a complete equipment/system. Refer to the equipment/system manual to obtain all the information relating to it and the safety rules on using the complete equipment/system. Using the AD1000 before having read and understood the instructions in this manual and the manual of the equipment/system incorporating the AD1000 is strictly prohibited.

  • Page 11: Safety Rules In The Manual

    WARNING, NOTE Indicates a warning or a note regarding key functions or useful information. Pay attention to the parts of text highlighted by this symbol. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 12: Safety Symbols

    Indicates a hazard with the risk of injury for the integrator/user or personnel in charge. Using suitable clothing such as shoes, overalls, gloves, etc. is mandatory. Pay the utmost attention to the signs and areas where this symbol appears. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 13: Terms And Acronyms Used

    However, in more general and valid terms, it is highlighted that: • Nidec ASI S.p.A. is not liable for damages or malfunctions in case of lack of maintenance, unauthorised replacement of equipment parts with non-original spare parts and different use of the AD1000 to that set out in this User and Maintenance Manual.

  • Page 14: Ad1000 Management

    All of the safety and protection devices must be maintained fully efficient in order to ensure they work properly. They must be immediately repaired or replaced by the after-sales assistance centre in case of damage or malfunction. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 15: Installation Overview And Diagram

    Developed by pump automation experts at Nidec, the versatile and reliable AD1000 is designed for optimum performance and reliability with minimal maintenance. While virtually ‘plug and play’ for standard applications, the AD1000’s flexible, modular design can also be easily configured to meet the most challenging applications.

  • Page 16: Installation Diagram

    CHECK CABLE INSTALLATION (POWER AND CONTROL) Paragraph 5.4.1 - Motor cables CHECK GROUND CONNECTIONS Paragraph 5.10.4.4 - Ground connection CHECK MOTOR AND CORRESPONDING CABLE INSULATION CHECK THE INSTALLATION COMMISSION THE DRIVE NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 17: Technical Data

    The AD1000 drive can control the motor in two different ways: Scalar V/f: for simple applications without speed feedback. Sensorless Vector V/f: for applications that require more dynamic performance and accuracy and without speed feedback. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 18: Identification Abbreviation

    From frame 350F to frame 520F the internal braking switch is not available. • Internal RFI filter: The RFI filter is optional for drives up to frame 028F; The RFI filter is standard for drives from frame 030F to 520F; NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 19: Plate

    22. HP motor power (CI.2) 10. Auxiliary voltage frequency 23. Output current (Cl.2) 11. Number of auxiliary voltage phases 24. Operating temperature 12. Auxiliary voltage rated current 25. SAP code 13. Notes NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 20: Admissible Environmental Conditions

    ), 11 ms (36 fts ) Free fall 250 mm (0.82 ft) (weight less than 100 kg / 220 lb) 100 mm (0.33 ft) (weight more than 100 kg / 220 lb) NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 21: Electrical Data

    For frames from 350F to 520F the internal braking switch is not available. The RFI filter is optional for drives up to frame 028F. The RFI filter is standard for drives from frame 030F. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 22: Switching Frequencies

    100% 100% AD1A350F 100% 100% 100% 100% AD1A370F 100% 100% 100% 100% AD1A440F 100% 100% AD1A480F 100% 100% AD1A520F 100% 100% The full current switching frequency is highlighted in bold. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 23: General Data

    Serial break Speed static accuracy: 0.01% (Sensorless) Watchdog Torque regulator response time: 5ms (Sensorless) External fault Overload: Cl. 1: 110% x60s every 10 min Cl. 2: 150% x60s every 10 min NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 24 1 +10V 10mA reference output protected against short circuit 1 -10V 10mA reference output protected against short circuit 1 R232 asynchronous serial port (ANSI protocol) 1 RS485 asynchronous serial port (Modbus RTU) NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 25: Losses And Ventilation Data

    AD1A125F 2700 2250 230V 50/60Hz AD1A150F 3300 2700 230V 50/60Hz AD1A166F 3300 2700 230V 50/60Hz AD1A210F 3350 2550 230V 50/60Hz AD1A260F 4000 2900 230V 50/60Hz AD1A290F 4350 3250 230V 50/60Hz NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 26 AD1000 fans are sized exclusively to deal with drive losses. To install them in a panel, supplementary load losses must also be considered. • For frames starting from AD1A125F and above, the user must provide fan power supply line protection elements. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 27: Overall Dimensions And Weights

    Frame IIIX 2.9.2 AD1A028F Taglia IIIL 2.9.2 AD1A30-036F Frame IIIN 2.9.3 AD1A045-053-066F Frame IVN 2.9.4 AD1A086-108F Frame VN 2.9.4 AD1A125-150-166F Frame VIN 2.9.4 AD1A210-260-290F Frame VII 2.9.5 AD1A350-370-440-480-520F Frame VIII 2.9.6 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 28: Frame I - Ad1A0P3-0P4-0P6F

    2 - TECHNICAL DATA AD1000 2.9.1 FRAME I - AD1A0P3-0P4-0P6F Peso Weight NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 29: Frames Ii-Iii-Iiix-Iiil - Ad1A008-011-015-018-022-028F

    AD1A011-015F 223.5 441.5 17.38 410.5 16.16 15.28 17.6 AD1A018-022F IIIX 245.5 9.67 466.5 18.37 435.5 17.15 417.5 16.44 17.6 AD1A028F IIIL 10.24 466.5 18.37 435.5 17.15 417.5 16.44 10.5 23.1 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 30: Frame Iiin - Ad1A030-036F

    2 - TECHNICAL DATA AD1000 2.9.3 FRAME IIIN - AD1A030-036F Peso Weight 70.55 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 31: Frames Ivn-Vn-Vin - Ad1A045-053-066-086-108-125-150-166F

    286.5 11.28 79.37 AD1A066F 10.39 286.5 11.28 286.5 11.28 88.19 AD1A086-108F 10.39 306.5 12.06 326.5 12.85 114.64 AD1A125F 10.78 326.5 12.85 326.5 12.85 AD1A150-166F 10.78 326.5 12.85 326.5 12.85 211.64 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 32: Frame Vii - Ad1A210-260-290F

    2 - TECHNICAL DATA AD1000 2.9.5 FRAME VII - AD1A210-260-290F Peso Weight NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 33: Frame Viii - Ad1A350-370-440-480-520F

    AD1000 2 - TECHNICAL DATA 2.9.6 FRAME VIII - AD1A350-370-440-480-520F Peso Weight NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 34 2 - TECHNICAL DATA AD1000 Version with carriage (option available only for VIII frames) The carriage is an option indicated by the 18th and 19th character of the identification code (see Chapter 2): NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 35: Terminal Block And Power Diagrams

    Taglia IIIL 2.10.5 AD1A30-036F Frame IIIN 2.10.6 AD1A045-053F Frame IVN 2.10.7 AD1A066F Frame IVN 2.10.8 AD1A086-108F Frame VN 2.10.9 AD1A125-150-166F Frame VIN 2.10.10 AD1A210-260-290F Frame VII 2.10.11 AD1A350-370-440-480-520F Frame VIII 2.10.12 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 36 From frame I to frame IIIL, braking resistance must be connected between R and + • From frame IIIN to frame VII, braking resistance must be connected between RE + and RE - NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 37: Frame I - Ad1A0P3-0P4-0P6F

    AD1000 2 - TECHNICAL DATA 2.10.1 FRAME I - AD1A0P3-0P4-0P6F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 38: Frame Ii - Ad1A008F

    2 - TECHNICAL DATA AD1000 2.10.2 FRAME II - AD1A008F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 39: Frame Iii - Ad1A011-015F

    AD1000 2 - TECHNICAL DATA 2.10.3 FRAME III - AD1A011-015F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 40: Frame Iiix - Ad1A018-022F

    2 - TECHNICAL DATA AD1000 2.10.4 FRAME IIIX - AD1A018-022F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 41: Frame Iiil - Ad1A028F

    AD1000 2 - TECHNICAL DATA 2.10.5 FRAME IIIL - AD1A028F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 42: Frame Iiin - Ad1A030-036F

    2 - TECHNICAL DATA AD1000 2.10.6 FRAME IIIN - AD1A030-036F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 43: Frame Ivn - Ad1A045-053F

    AD1000 2 - TECHNICAL DATA 2.10.7 FRAME IVN - AD1A045-053F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 44: Frame Ivn - Ad1A066F

    2 - TECHNICAL DATA AD1000 2.10.8 FRAME IVN - AD1A066F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 45: Frame Vn - Ad1A086-108F

    AD1000 2 - TECHNICAL DATA 2.10.9 FRAME VN - AD1A086-108F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 46: Frame Vin - Ad1A125-150-166F

    2 - TECHNICAL DATA AD1000 2.10.10 FRAME VIN - AD1A125-150-166F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 47: Frame Vii - Ad1A210-260-290F

    AD1000 2 - TECHNICAL DATA 2.10.11 FRAME VII - AD1A210-260-290F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 48 2 - TECHNICAL DATA AD1000 Without dynamic brake With dynamic brake NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 49: Frame Viii - Ad1A350-370-440-480-520F

    AD1000 2 - TECHNICAL DATA 2.10.12 FRAME VIII - AD1A350-370-440-480-520F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 50 2 - TECHNICAL DATA AD1000 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 51: Application Notes

    Figure 3.1.2 - AD1000 diagram (045F - 520F) NOTE The preload contactor in some frames is positioned on the DC Bus negative. Refer to the power layouts in chapter 2. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 52: General Formulas That Describe Drive Operation

    3 - APPLICATION NOTES AD1000 General formulas that describe drive operation Figure 3.2.3 Single-line diagram of a drive with an induction motor NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 53 Power watt 0.00134 lb-ft/min 0.0000303 746.00 watt 33000.00 lb-ft/min BTU/hour 0.293 watt Temperature degrees C = (degrees F-32) x 5/9) degrees F = (degrees C x 9/5) + 32 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 54: Drive Selection

    • Submersible pumps. The rated current of these motors is greater than the standard. • Single phase motors. AD1000s are not designed to control single phase motors. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 55: Motor Selection

    Motor self-excitation. This phenomenon is destructive and dangerous, it damages the machine and can occur if an LC filter is connected to the drive output and is not properly sized. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 56 20% increase in the mains voltage. Said increment must be considered when establishing the insulation requirements. Example: For a 400V motor, insulation criteria for a 480V power supply must be adopted. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 57: General Information

    The AD1000 drive was designed, built and tested in compliance with the “ESSENTIAL SAFETY REQUIREMENTS” contained in Annex I of European Directive 2006/42 EC. The following table shows the Technical Standards used as references to design, build and test the drive. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 58: Standard Of Reference

    For information on calibrating the trip threshold to overload time etc., see paragraph 2.5, table 2.5.1 and the programming manual. 7. The AD1000 drive requires overload static protection at drive output and DC side short circuit static protection. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 59: General Information

    AD1000s are open type devices and must be installed strictly following the instructions in this manual and in total compliance with the existing standards and regulations. • Never store flammable material inside, on or near the drive. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 60 The boards must not come into contact with highly insulating materials like plastic sheets, insulating surfaces, synthetic fabric parts. • The boards must only be positioned on conductive surfaces. • The boards must be packaged in conductive sheets before being shipped. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 61: Requirements In The Event Of Electrical Installation

    The AD1000 contains components that are sensitive to electrostatic charges; said components could be damaged if not handled appropriately. Appropriate precautions against electrostatic discharges (ESD) must be taken when servicing or replacing the electronic boards: NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 62: Regulations In The Event Of Maintenance

    Regulations in the event of maintenance SAFETY PRECAUTIONS All electrical maintenance and installation operations on the AD1000 must be done by qualified technical personnel. Nidec ASI S.p.A. is not liable for damages due to improper or unauthorised maintenance. HAZARD! RISK OF DEATH OR ELECTRIC SHOCK! The following safety measure must absolutely be adopted before servicing the unit: •...

  • Page 63: General Information - Standards

    AD1000 is incorporated/installed; in particular, personnel must know and have experience with the operating features and position of all the AD1000 controls. WARNING The AD1000 supplied by Nidec ASI S.p.A. is exclusively intended for professional use by trained, informed, educated personnel qualified to correctly incorporate, install and use it. HAZARD Unauthorised tampering with or replacing one or more parts of the AD1000, using accessories that modify its use and using spare parts other those specified can lead to injuries.

  • Page 64: Intended Use And Limits Of Use

    In this regard, the manufacturer declines all liability in case of damages to property and/or people and voids any warranty. HAZARD Using the AD1000 for uses not expressly provided for and documented by Nidec ASI S.p.A. or in environmental, electrical, mechanical, physical, hydraulic conditions different to those prescribed by Nidec ASI S.p.A. constitutes improper use.
  • Page 65 AD1000 are obliged to follow them. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 66: Environmental Working Conditions

    Using the AD1000, the associated control systems and the activation equipment in different environmental conditions to those specified in this manual is not permitted. Specifically, the AD1000 must work in the specific environmental conditions indicated in 2.4. 4.4.1 Vibrations See 2.4 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 67: Environmental Storage Conditions

    The equipment must be kept in its original packaging and in a clean dry place. If the storage site does not fall within the standard specifications, special packaging and protective devices can be agreed upon with Nidec ASI S.p.A. The equipment must always be protected with tarpaulins/air tight covers; also make sure that the environmental parameters (particularly temperature and humidity) remain within the above range.

  • Page 68: Fixed Protections

    The AD1000 has a ventilation system fitted with fixed guards (grids); these, positioned in the suction/delivery areas with exclusive access for maintenance, require the use of special tools to remove them. ADDITIONAL INFORMATION Periodically check the integrity of the fixed guards and the corresponding fastenings to the structure. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 69: Personal Protective Equipment (Ppe)

    It is the specific responsibility of the final integrator/user to make sure that personnel in charge are duly trained on the residual risks related to the treated process and use the PPE listed in the product safety sheets, as well as those listed here. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 70: Residual Risks

    AD1000 mandatory, before doing any work on it. WARNING It is strictly forbidden to carry out whatsoever electrical adjustment as it may create unexpected additional dangers and risks. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 71: Fire

    Messily storing material can generally constitute a tripping hazard and can partially or totally restrict escape routes, should they be needed. • Make sure operating spaces, transit paths and escape routes are free from obstacles and in compliance with the current regulations. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 72: Circuit Faults

    Any excessive or abnormal vibrations may be associated to a malfunction of the rotary part of devices such as pumps, etc. Should this condition occur, immediately inform the maintenance personnel and stop the AD1000 for testing/repair. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 73: Additional Hazard Instructions

    The AD1000 is not equipped with any cut off and/or isolating devices on the engine side and internal circuits. All AD1000 electrical connection terminals must always be considered live unless the operating means (not supplied by Nidec ASI S.p.A.) for the installation in which the AD1000 is incorporated and/or integrated ensure the power supply on the motor side and on the low and medium voltage power supply side is cut off.
  • Page 74 Caution! The AD1000 must be adequately grounded before connecting any power supply sources and operating with the AD1000 itself. • Do not disconnect any earthing and/or connection cables. • Regularly check earthing during maintenance and whenever there are any doubts. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 75: Additional Warning Instructions

    Therefore, this task/function is prohibited by the manufacturer. The user/integrator must provide appropriate "PPE" (such as ear plugs, earmuffs and face protection glasses) for exposed people. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 76: Warning Plates

    Warning plates Based on the various residual risks identified for the AD1000, Nidec ASI S.p.A. has fitted the equipment with hazard, warning and mandatory signs defined in accordance with the European standard on graphic symbols to be used on systems (Directive 92/58/EEC). The plates in question are located in easily visible positions.

  • Page 77: Reception, Storage And Installation

    All the metal surfaces must be protected to prevent them from being damaged. Frame IVN, VN, VIN handling NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 78: Storage

    The drives are not waterproof and must never be stored outdoors. Table 2.4.1 shows the nominal environmental conditions. Operators should contact the Nidec ASI S.p.A. production team with any doubts they might have for particular locations.

  • Page 79: Mechanical Installation

    Should the drives be assembled stacked, prevent the upper module from being affected by the hot air from the underlying module. NOTE For frames from AD1A210F to AD1A520F, once the drive has been installed in the panel, the lifting eyebolts must be removed. Example NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 80: Frames Vii And Viii Installation

    (1) and then rotated (2). Do the same for the right bracket (3 and 4). Once installed inside the panel, the locking bracket must be rotated, using the specific nut (5 and 6). NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 81: Free Space Near The Drive

    200 / 7.8 100 / 3.9 100 / 3.9 200 / 7.8 50 / 2 100 / 3.9 300 / 11.8 VIII 50 / 2 100 / 3.9 300 / 11.8 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 82 Panel interior Prevent hot air from circulating inside the panel with closing plates as illustrated in the drawing. Gaskets are usually not required. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 83 The figure shows the position of the installation holes for a typical frame; for details on the various frames, see paragraph 2.9 “Overall dimensions and weights”. Figure 5.3.2 - position of the installation holes NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 84: Ipxx Degree

    Dust tight, complete protection against accidental Protection against water projected in powerful jets (for contact. example, in the event of rough seas) Protection against immersion Protection against prolonged immersion NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 85: Access To The Terminal Blocks

    AD1A - frames I, II, III, IIIX, IIIL AD1A - frames IIIN, IVN, VN, VIN For the overall dimensions, see paragraph 2.9 AD1A - frames VII, VIII NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 86: Electrical Installation

    In the event of protection towards the ground, use a device that is minimally sensitive to high frequencies so as to prevent false trips. The threshold current should be greater than 200mA and the trip time at least 0.1s. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 87 AD1000 5 - RECEPTION, STORAGE AND INSTALLATION Figure 5.4.1 Power connections AD1A0P3F-028F AD1A030F-166F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 88 5 - RECEPTION, STORAGE AND INSTALLATION AD1000 AD1A210F-520F NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 89: Power Cables, Motor Cables And Power Fuses

    (1) - AC side fuses: for the EC market, normal gG fuses can be used with current calibre equal to 1.3 times the AD1000 rated current (a) - Standard SCCR - Short Circuit Current Rating according to the UL508C standard NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 90 5.4.1.1. **Cable cross-sections in the table are approximate. Refer to local wiring rules for proper sizing. In some cases, a larger cross-section may be required to prevent excessive voltage drops. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 91 5.4.1.2, supplied with the drive. In addition, upstream of the fuses in table 5.4.1.2, the user must install non-renewable cartridge fuses (JDDZ/JDDZ7), class J, with the appropriate voltage and current calibre. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 92: Auxiliary Power Supplies

    AD1A125-520F drives require a 50/60 Hz single phase 230Vac auxiliary power supply for the fan (see table 2.8.1 for absorption data). Make sure the auxiliary power supply is connected with the proper input voltage setting before enabling the drive. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 93: Reactors

    : average value of V : voltage imbalance In this example the reactor is not required The power supply line Power and the inverter Power are included in the highlighted area. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 94: Output Reactors

    Limit the length of the motor cables so as not to exceed a voltage drop of 3-5% to the rated current. In the event of parallel motors, the sum of the length of the various cables must be considered. The input and output reactor codes are shown in Table 5.5.1 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 95: Rfi Filters

    For 008F frame drives, the filters marked as internal do not change the overall drive dimensions. If marked as external, they must be installed by the customer For frames 0P3F, 0P4F and 0P6F, the drive dimensions are as follows. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 96 1000248145 1000248144 AD1A053F 1000248146 1000248145 AD1A066F 1000248147 1000248146 INTEGRATED INTEGRATED for category C2 AD1A086F 1000248148 1000248147 AD1A108F 1000248149 1000248148 AD1A125F 1000248150 1000248149 AD1A150F 1000248151 1000248150 AD1A166F 1000248152 1000248151 * External NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 97: Voltage Protection

    To be CSA qualified, the inverter must be equipped with external Transient Voltage Surge Suppressors (VZCA2/VZCA8) with contact for remote signalling. Maximum continuative Maximum discharge Tipo Configuration Surge protection operating voltage current 1 CA L-L/L-PE 1500 V 4000 V 40 kA NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 98: Control Section

    Used by EPLD to signal a watchdog status On = Watchdog status Green 6.5V Power supply 6.5Vdc power supply ON = 6.5Vdc present Green 24V I/O Digital I/O interface 24V power supply ON = 24V present NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 99 If the analogue input and digital input expansion board (GIABA) or the analogue input and digital output expansion board (GIABB) are installed, the Basis board P30 jumper is no longer accessible. In this case, the expansion board P30 jumper must be opened and, if necessary, used. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 100 Input Expansion or I/O Expansion Keypad Control terminal block NOTE: The J12 control terminal block is also indicated as an ME (External Terminal Block) in this manual and in the programming manual. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 101 AI 2+ J12-37 AI/AO ground 0V analogue I/O NOTE: The J12 control terminal block is also indicated as an ME (External Terminal Block) in this manual and in the programming manual. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 102 5 - RECEPTION, STORAGE AND INSTALLATION AD1000 *Note: with inductive load (relay coil), put a suitable diode in parallel. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 103 AD1000 5 - RECEPTION, STORAGE AND INSTALLATION Figure 5.6.2 Control terminal block NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 104 5 - RECEPTION, STORAGE AND INSTALLATION AD1000 Figure 5.6.3 Example of AD1000 connection with Basis board NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 105: Expansion Board

    P30 jumper must be opened and, if necessary, used. The board is an option indicated by the letter A in the 14th character of the identification code (see Chapter 2): NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 106 NOTE: The J1E terminal block is also indicated as an ME (External Terminal Block) in this manual and in the programming manual. GIABA board: GIABA board installed on the BASIS board: NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 107: Analogue Input And Digital Output And Rtc Expansion Board (Giabb)

    P30 jumper must be opened and, if necessary, used. The board is an option indicated by the letter B in the 14th character of the identification code (see Chapter 2): NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 108 Differential configuration (Rin=33kΩ) J1-11 AI3+ J1-12 AI3 - Connection for relay expansion board J11-38 +24V 24V digital outputs J11-39 0V digital outputs GIABB board: GIABB board installed on the BASIS control board: NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 109 RELAY EXPANSION BOARD CONNECTORS Terminal Output Contact Reserved Reserved Reserved Out DO4 Out DO5 Out DO6 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Relay expansion board NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 110: Modbus Tcp And Profibus Expansion Board (Eth-Profi)

    The board is an option indicated by the letter P in the 13th character of the identification code (see Chapter 2): ETH-PROFI board: ETH-PROFI board installed on the BASIS board: NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 111: Installation Check List

    Control connections appropriately: connected tightened Suitable input fuses installed. There are no compensation capacitors in the motor connections. There are no tools or other outside objects inside the casing. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 112: Installation Instructions In Compliance With The Emc Directive

    Warnings for the user instructions: This type of PDS cannot be used on a low voltage public mains that powers domestic premises. Use on said mains causes radio frequency interferences. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 113 Select and install the accessories in compliance with the manufacturer’s instructions. • 360° grounding on the motor axis. See the specific manuals for the individual products. • Proper inner wiring methods. • Special attention to the grounding methods. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 114: Rfi Filters For Radio Frequency Interferences

    (>30.X), the network will be connected to the ground potential via the drive EMC filter capacitors. This can cause dangerous situations or damage the unit. The filter must not be connected to the drive output terminals (motor side). NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 115 If a drive with corresponding RFI filter is installed on an IT network (network isolated from the ground or a grounded network with high resistance (>30Ω),) the network will be connected to the ground potential via the drive EMC filter capacitors. This can cause dangerous situations or damage the unit. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 116: Ad1000 Compliance With Iec 61800-3

    2. There is an EMC plan to prevent interferences for the specific installation. 3. Power and control cables are provided as required by the Manual. 4. The drive was installed following the instructions in the Manual. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 117: Motor Cables

    Recommended cable Symmetrical shielded cable: shield with 50% greater cross-section than the cross-section of every phase conductor (a separate PE conductor is only necessary if the cable shielding conductivity is insufficient). NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 118 Due to ground dispersion current and high switching frequency, very long motor cables can cause the ground fault detection device to trip. Replace the device with a less sensitive one or power the drive with a specific transformer. Drive-motor connections with two shielded cables NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 119 The cable running from the drive to the derivation terminal block without shielding must be as short as possible. AD1A030-166 drives have an internal ferrite core in output. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 120 The power cable shield can be used as ground cable only if it has a cross-section suited to the safety standards. AD1A AD1A AD1A AD1A AD1A AD1A b) Acceptable connection a) Preferred connection NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 121: Options And Accessories

    6 - OPTIONS AND ACCESSORIES OPTIONS AND ACCESSORIES Introduction The AD1000 has several options and accessories. Some of the most requested ones are illustrated in this chapter; contact Nidec Asi for special requests. Options (request when ordering the AD1000): •...

  • Page 122: Dynamic Braking

    The braking device is able to manage continuous braking power calculated for 50% of the rated motor power (see paragraph 2.5 “Electrical data”). NOTE: - For critical performance cycles (i.e. lifting applications), consult the manufacturer. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 123 1) User’s responsibility * Sized for emergency braking (1.5 I –CI.2 for 60 s) Braking units are available for installation outside the drive called “GTBU .. F/K” (See IMGT30006EN/IT manual) NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 124: Resistor Installation And Connection

    Due to safety issues, it is mandatory to provide a contactor on the drive power supply input and make sure it opens if the resistor overheats. Figure 6.2.2.1 shows a simple connection example. Figure 6.2.2.1 Example of contactor connection NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 125: Choosing The Resistor

    Rated braking DC voltage (See the values shown in table 6.1-3) ⋅ ⋅ 2π − In the worst case M = 1.5 M ⋅ ⋅ ⋅ ⋅ 0.10472 ⋅ ⋅ ⋅ 0.10472 ⋅ NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 126 380 to 480V After calculations, the braking resistor can be selected using the following values: • ohm value (Ω), • braking power (J), • work cycle, • 1200 Volt peak ground voltage. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 127: Keypad

    Code 8000001597. See programming user manual. Backlit graphic LCD AFK keypad. REMOTE CONTROL OPERATOR Fault STOP AUTO RESET Motor Drive Stab Logs Auto Main Enter DvProt Comm Meter Canc. Help SHIFT NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 128: Installation On Panel Door

    Installing the shell requires the following hollow on the panel door. Keypad degree of protection: IP54 Shell degree of protection: IP54 (with gaskets on the hollow - code1000072882 and on the connecting hole - code 1000072881) NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 129: Sto Safety Function (Safe Torque Off)

    The STO option must be defined before ordering the inverter (factory installed and tested); when the STO function is installed, the DO3 relay programmable digital output is no longer available. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 130: Safety Functions And Corresponding Level

    Full STO function (version T) block diagram for Basis control board Single Channel STO function (version D) block diagram for Basis control board NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 131 See paragraph 2.4 “Configuration” in the MIM046 document rev.21 for further information regarding: − the actions to take should a failure be identified; − trip times; NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 132: Sinusoidal Filter

    On frames with a default switching frequency of 1.5kHz, remember to reset the frequency at 2kHz (Switching Freq [06.25] parameter). See paragraph 2.6 for the switching frequencies and the programming manual. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 133 AD3A260F 1000250310 1000250309 AD3A290F 1000250316 1000250310 AD3A350F VIII 1000250317 1000250316 AD3A370F VIII 1000250318 1000250316 AD3A440F VIII 1000250321 1000250317 AD3A480F VIII 1000250322 1000250318 AD3A520F VIII 1000250322 1000250319 Table 6.5.1 Sinusoidal filters NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 134: Carriage

    The carriage is an option, available only for VIII frames, indicated by the 18th and 19th character in the identification code (see Chapter 2) and can be supplied with or without output reactor (CR/CN). See paragraph 2.8 for the full measures. Example: NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 135: External Power Supply To The Control

    For drives with frame from AD1A030F to AD1A520F, the feeder board is installed inside the converter without changing its physical dimensions. For smaller frame drives, the dimensions and terminal blocks are different to those of standard converters and are shown below. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 136 6 - OPTIONS AND ACCESSORIES AD1000 FRAME I AD1A0P3-0P4-0P6 FRAMES II-III-IIIX-IIIL AD1A008-028 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 137: Preventive Maintenance

    Check AD1000-PM003 6 months Drive AD1000 Radiator Cleaning AD1000-PM004 1 month 3 years after first installation and Drive AD1000 Fans Cleaning AD1000-PM005 then every year Drive AD1000 Capacitors Formatting AD1000-PM006 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 138: Ad1000 - Pm001 Drive

    • the boards and dust and condensate-free; • the insulation is not damaged or discoloured; • the vents or areas near the drive fans are not obstructed. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 139: Ad1000 - Pm002 Drive

    The electronic boards do not require particular maintenance operations. Periodically remove dust without using compressed air, as there are components that are sensitive to electrostatic loads installed on the boards. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 140: Ad1000 - Pm003 Drive

    IGBT INPUT BRIDGE Multimeter + test probe - Vc - Vc - Vc - Vc Multimeter - test probe Component 0.25 ÷ 0.4 Vdc 0.35 ÷ 0.5 Vdc Correct value NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...

  • Page 141: Ad1000 - Pm004 Drive

    Power off the devices by disconnecting the power supply. Access the radiator. Remove the dirt outside. Remove the dirt from the radiator using an industrial vacuum cleaner. Remove obstructions and/or impurities. Restore power. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 142 Power off the devices by disconnecting the power supply. Access the fan. Remove the dirt outside. Remove the dirt from the radiator using an industrial vacuum cleaner. Remove obstructions and/or impurities. Restore power. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 143 Power the drive DC bus with a diode three-phase bridge with a load resistor in series as illustrated in Figure 7.2. (P = Rectifier; R = Load resistor; C = Capacitor). Refer to Figure 7.1 for formatting time. NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL IMAD10002EN...
  • Page 144 Failure to do this maintenance procedure can, in the worst case scenario, lead to capacitor and drive failure. For further information, contact Nidec ASI S.p.A. Customer Assistance. Figure 7.2 NIDEC ASI S.P.A. – AD1000 USER AND MAINTENANCE MANUAL...

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