Nidec 5200250 Power Installation Manual
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Nidec 5200250 Power Installation Manual

Unidrive m / hs
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Frame 5 to 6
Power Installation Guide
Commander C200
& C300
Unidrive M / HS
Part Number: 0478-0255-09
Issue: 9

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Summary of Contents for Nidec 5200250

  • Page 1 Frame 5 to 6 Power Installation Guide Commander C200 & C300 Unidrive M / HS Part Number: 0478-0255-09 Issue: 9...
  • Page 2 European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation. Further information on our compliance with REACH can be found at: http://www.drive-setup.com/reach Registered Office Nidec Control Techniques Ltd The Gro Newtown Powys SY16 3BE Registered in England and Wales.
  • Page 3 All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher. Copyright © December 2018 Nidec Control Techniques Ltd...

  • Page 4: Table Of Contents

    Contents Safety information ..................12 Warnings, Cautions and Notes ................12 Important safety information. Hazards. Competence of designers and installers ..12 Responsibility ......................12 Compliance with regulations ..................12 Electrical hazards ....................13 Stored electrical charge ..................13 Mechanical hazards ....................13 Access to equipment ....................13 Environmental limits ....................13 1.10 Hazardous environments ..................13 1.11...
  • Page 5 UL listing information ................107 UL file reference ....................107 Option modules, kits and accessories ..............107 Enclosure ratings ....................107 Mounting ......................107 Environment ......................108 Electrical Installation .................... 108 Motor overload protection and thermal memory retention ........108 Electrical supply ....................109 External Class 2 supply ..................
  • Page 6 EU Declaration of Conformity Control Techniques Ltd The Gro Newtown Powys SY16 3BE This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant European Union harmonization legislation. The declaration applies to the variable speed drive products shown below: Model Interpretation...
  • Page 7 EU Declaration of Conformity Nidec Control Techniques Ltd The Gro Newtown Powys SY16 3BE This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant European Union harmonization legislation. The declaration applies to the variable...
  • Page 8 EU Declaration of Conformity (including 2006 Machinery Directive) Control Techniques Ltd The Gro Newtown Powys SY16 3BE This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant European Union harmonization legislation. The declaration applies to the variable speed drive products shown below: Model Interpretation...
  • Page 9 Person authorised to complete the technical file: P Knight Conformity Engineer Newtown, Powys, UK G. Williams Vice President, Technology Date: 15th February 2016 Place: Newtown, Powys, UK IMPORTANT NOTICE These electronic drive products are intended to be used with appropriate motors, controllers, electrical protection components and other equipment to form complete end products or systems.
  • Page 10 EU Declaration of Conformity (including 2006 Machinery Directive) Nidec Control Techniques Ltd The Gro Newtown Powys SY16 3BE This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant European Union harmonization legislation. The declaration applies to the variable...
  • Page 11 Person authorised to complete the technical file: P Knight Conformity Engineer Newtown, Powys, UK Jon Holman-White Director of Research and Development Date: 9th October 2018 Place: Newtown, Powys, UK IMPORTANT NOTICE hese electronic drive products are intended to be used with appropriate motors, controllers, electrical protection components and other equipment to form complete end products or systems.

  • Page 12: Safety Information

    Safety information Warnings, Cautions and Notes A Warning contains information which is essential for avoiding a safety hazard. WARNING A Caution contains information which is necessary for avoiding a risk of damage to the product or other equipment. CAUTION A Note contains information, which helps to ensure correct operation of the product. NOTE Important safety information.

  • Page 13: Electrical Hazards

    Electrical hazards The voltages used in the drive can cause severe electrical shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to the drive. Hazardous voltage may be present in any of the following locations: •...

  • Page 14: Motor

    1.11 Motor The safety of the motor under variable speed conditions must be ensured. To avoid the risk of physical injury, do not exceed the maximum specified speed of the motor. Low speeds may cause the motor to overheat because the cooling fan becomes less effective, causing a fire hazard.

  • Page 15: Product Information

    Product information Introduction This guide provides the information necessary to install the following drive models: Unidrive Mxxx frame 5 to 6 Unidrive HSxx frame 5 to 6 Commander Cxxx frame 5 to 6 This guide focuses on the drive power section, for example: electrical installation of the supply / motor cables and mechanical installation of the drive.

  • Page 16: Nameplate Description

    Nameplate description Figure 2-2 Typical drive rating labels (Unidrive M600 labels illustrated) Heavy Duty Frame current rating size Model Refer to M600-032 00050 A User Guide Voltage Drive format Key to approvals Heavy Duty / Input Date code Normal Duty frequency power rating Input voltage...

  • Page 17: Ratings

    Ratings Fuses The AC supply to the drive must be installed with suitable protection against overload and short-circuits. The following section shows recommended fuse ratings. Failure to observe this requirement will cause risk of fire. WARNING Nominal cables sizes below are based on the cable installation method B2 (ref: IEC60364- NOTE 5-52:2001) unless otherwise specified, and are provided as a guide only.
  • Page 18 Table 2-4 Protective ground cable ratings Input phase conductor size Minimum ground conductor size Either 10 mm or two conductors of the same cross-sectional area as the input ≤ 10 mm phase conductor The same cross-sectional area as the input phase conductor >...

  • Page 19: Drive Features

    Drive features Figure 2-3 Features of the drive power section 1. Braking terminal (for external brake resistor) 2. Internal EMC filter 3. DC bus + 4. DC bus - 5. Motor connections 6. AC supply connections 7. Ground connections 8. Braking terminal for heatsink mounted brake resistor (size 5 only, M600 and above) Unidrive M/HS Frame 5 to 6 Power Installation Guide Issue Number: 9...
  • Page 20 2.5.1 Items supplied with the drive The drive is supplied with a copy of the Power Installation Guide and a copy of the Control Getting Started Guide, a safety information booklet, the Certificate of Quality and an accessory kit box including the items shown in Table 2-6.

  • Page 21: Mechanical Installation

    If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Nidec Industrial Automation or their authorized distributor.

  • Page 22: Planning The Installation

    Planning the installation The following considerations must be made when planning the installation: 3.2.1 Access Access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with. The IP (Ingress Protection) rating of the drive is installation dependent. For further information, refer to section 3.8 Enclosing standard drive for high environmental protection on page 37.
  • Page 23 Figure 3-1 Fire enclosure bottom layout Drive The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by having no openings or by having a baffle construction. This means that openings for cables etc.

  • Page 24: Terminal Cover Removal

    If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Nidec Industrial Automation or their authorized distributor.
  • Page 25 Figure 3-4 Removing the size 5 terminal covers 1. Control terminal cover 2. DC / Braking terminal cover right The Control terminal cover must be removed before removal of the DC / Braking terminal cover right. When replacing the terminal covers, the screws should be tightened to a maximum torque of 1 N m (0.7 lb ft).
  • Page 26 3.3.2 Removing the finger-guard and DC terminal cover break-outs Figure 3-6 Removing the finger-guard break-outs A: All sizes. B: Size 5 only. C: Size 6 only. Place finger-guard on a flat solid surface and hit relevant break-outs with hammer as shown (1). Continue until all required break-outs are removed (2).

  • Page 27: Dimensions And Mounting Methods

    Dimensions and mounting methods Drive sizes 5 to 6 can be either surface or through-panel mounted. Size 5 can in addition be tile mounted using the appropriate brackets. If the drive has been used at high load levels for a period of time, the heatsink can reach temperatures in excess of 70 °C (158 °F).
  • Page 28 3.4.2 Surface mounting Figure 3-8 Surface mounting dimensions (size 5 to 6) 9 mm 8 mm 7.0 mm 196 mm 106 mm (4.17 in) (0.35 in) (0.32 in) (0.28 in) (7.72 in) 6.0 mm (0.24 in) 378 mm (14.88 in) Æ...
  • Page 29 3.4.3 Through-panel mounting The drive can be through panel mounted using appropriate brackets. The through panel mounting kit is not supplied with the drive and can be purchased separately, below are the relevant part numbers: Size CT part number 3470-0067 3470-0055 If the drive has been used at high load levels for a period of time, the heatsink can reach temperatures in excess of 70 °C (158 °F).
  • Page 30 3.4.4 Mounting brackets Table 3-1 Mounting brackets Frame Surface mounting kit Through-panel mounting kit size (supplied with drive) (option) x 2* Hole size: 6.5 mm (0.26 in) Hole size: 5.5 mm (0.22 in) x 2* Hole size: 5.2 mm (0.21 in) Hole size: 6.5 mm (0.26 in) * Surface mounting brackets are also used when through panel mounting, see section 3.8 Enclosing standard drive for high environmental protection on page 37 for further details.

  • Page 31: Enclosure For Standard Drives

    Enclosure for standard drives Figure 3-10 Recommended spacing between the drives Enclosure Table 3-2 Spacing required between the drives (without high IP bung) Spacing (A) Drive Size 40 °C 50 °C* 0 mm (0.00 in) 30 mm (1.18 in) 0 mm (0.00 in) * 50 °C derating applies, refer to Table 5-6 Maximum permissible continuous output current @ 50 °C (122 °F) on page When through-panel mounted, ideally drives should be spaced 30 mm (1.18 in) to...
  • Page 32 3.5.1 Enclosure layout Please observe the clearances in the diagram below taking into account any appropriate notes for other devices / auxiliary equipment when planning the installation. Figure 3-11 Enclosure layout Locate optional braking Optional braking resistor and overload resistor external to cubicle (preferably near to or on top of the cubicle).
  • Page 33 3.5.2 Enclosure sizing 1. Add the dissipation figures from section 5.1.3 Power dissipation on page 87 for each drive that is to be installed in the enclosure. 2. If an external EMC filter is to be used with each drive, add the dissipation figures from section 5.2.1 EMC filter ratings on page 105 for each external EMC filter that is to be installed in the enclosure.
  • Page 34 Figure 3-12 Enclosure having front, sides and top panels free to dissipate heat Insert the following values: 40 C 30 C 392.4 W The minimum required heat conducting area is then: 392.4 -------------------------------- -   5.5 40 30 – = 7.135 m (77.8 ft ) (1 m...
  • Page 35 Where: Air-flow in m per hour (1 m /hr = 0.59 ft /min) Maximum expected temperature in C outside the enclosure Maximum permissible temperature in C inside the enclosure Power in Watts dissipated by all heat sources in the enclosure ------ - Ratio of Where:...

  • Page 36: Enclosure Design And Drive Ambient Temperature

    Enclosure design and drive ambient temperature Drive derating is required for operation in high ambient temperatures Totally enclosing or through panel mounting the drive in either a sealed cabinet (no airflow) or in a well ventilated cabinet makes a significant difference on drive cooling. The chosen method affects the ambient temperature value (T ) which should be used for any rate...

  • Page 37: Enclosing Standard Drive For High Environmental Protection

    Enclosing standard drive for high environmental protection An explanation of environmental protection rating is provided in section 5.1.10 IP / UL Rating on page 92. The standard drive is rated to IP20 pollution degree 2 (dry, non-conductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP65 rating (NEMA 12) at the rear of the heatsink for through-panel mounting (some current derating is required).
  • Page 38 Figure 3-14 Installing the gasket Enclosure rear wall Gasket Drive To seal the space between the drive and the backplate, use two sealing brackets as shown in Figure 3-15. Figure 3-15 Through panel mounting Enclosure rear wall Through panel securing bracket Through panel securing bracket Unidrive M/HS Frame 5 to 6 Power Installation Guide...

  • Page 39: Installation Of High Ip Insert For Size 5

    Installation of high IP insert for size 5 The standard drive is rated to IP20 pollution degree 2 (dry, non-conductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP65 rating (NEMA 12) at the rear of the heatsink for through-panel mounting (some current derating is required).
  • Page 40 Table 3-4 Environment considerations Environment High IP insert Comments Clean Not installed Dry, dusty (non-conductive) Installed Dry, dusty (conductive) Installed Regular cleaning recommended IP65 compliance Installed A current derating must be applied to the size 5 drive if the high IP insert is installed. NOTE Derating information is provided in Table 5-5 Maximum permissible continuous output current @ 40 °C (104 °F) ambient with high IP insert installed on page 85.

  • Page 41: Internal Braking Resistor

    3.10 Internal braking resistor Size 5 has been designed with an optional space-saving heatsink mounted resistor. The resistor can be installed within the heatsink fins of the drive. When the heatsink resistor is used, an external thermal protection device is not required as the resistor is designed such that it will fail safely under any fault conditions.
  • Page 42 Figure 3-18 Brake resistor with the mounting bracket 1. Ground connection (1 x M4 nut and washer). 2. Attaching the brake resistor to the mounting bracket (using 2 x M4 screws and nuts). Figure 3-19 Mounting bracket dimensions 118 mm (4.65 in) 15.5 mm (0.61 in) Æ...

  • Page 43: External Emc Filter

    3.11 External EMC filter The external EMC filters for sizes 5 to 6 can be footprint or bookcase mounted as shown below. Figure 3-21 Footprint mounting the EMC filter Figure 3-22 Bookcase mounting the EMC filter 3.11.1 Optional external EMC filters Table 3-6 EMC filter cross reference Model CT part number...
  • Page 44 Figure 3-23 External EMC filter (size 5 to 6) X: Threaded holes for footprint V: Ground stud Y: Footprint mounting hole diameter mounting of the drive Z: Bookcase mounting slot diameter. CS: Cable size Table 3-8 Size 5 external EMC filter dimensions CT part number 4200-0312...

  • Page 45: Terminal Size And Torque Settings

    Table 3-11 Fastener details for drive footprint mounting on external EMC filter Type Size 5 and 6 Screw specification Property class 8.8. standard metric, coarse thread Thread size Length (mm) Washer Helical spring, split spring or conical spring Torque (N m) 10.0 3.12 Terminal size and torque settings...
  • Page 46 3.13.1 Fan removal procedure Figure 3-24 Removal of the size 5 heatsink fan Ensure the fan cable is disconnected from the drive prior to attempting fan removal. • Press the two tabs inwards (1) to release the fan from the drive frame. •...
  • Page 47 Figure 3-26 Removal of the size 6 auxiliary fan • Press the tabs (1) inwards to release the fan assembly from the drive mid cover. • Use the tabs (1) to withdraw the fan from the drive by pulling the fan assembly forward and tilting it at a slight angle (2).

  • Page 48: Electrical Installation

    If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Nidec Industrial Automation or their authorized distributor.

  • Page 49: Power And Ground Connections

    Power and ground connections Figure 4-1 Size 5 power and ground connections DC / Brake connections Optional heatsink mounted brake resistor (M600 and above) Thermal overload protection Optional external device braking resistor DC + DC - AC Connections Motor Connections Optional EMC filter Optional...
  • Page 50 Figure 4-2 Size 6 power and ground connections DC Connections (DC and braking) Thermal overload protection Optional device braking resistor DC - DC + AC Connections Motor Connections Ground connection studs Optional EMC filter Optional line reactor Fuses Motor Optional ground Mains connection Supply...

  • Page 51: Ac Supply Requirements

    4.1.1 Ground connections Electrochemical corrosion of grounding terminals Ensure that grounding terminals are protected against corrosion i.e. as could be caused by condensation. WARNING The drive must be connected to the system ground of the AC supply. The ground wiring must conform to local regulations and codes of practice.
  • Page 52 A ground fault in the supply has no effect in any case. If the motor must continue to run with a ground fault in its own circuit then an input isolating transformer must be provided and if an EMC filter is required it must be located in the primary circuit.

  • Page 53: Supplying The Drive With Dc

    Table 4-2 2 % line reactors Line Voltage reactor Drive Inductance Weight Length Width Height Line reactor CT Part rating current model designation number rating number 05200250 INL2008 4401-0226 0.26 3.30 06200330 INL2004 4401-0146 48.8 0.17 06200440 INL2005 4401-0147 56.6 0.15 05400270 INL4013...

  • Page 54: 24 Vdc Supply

    Figure 4-4 DC bus paralleling (size 3 shown) There are limitations to the combinations of drives which can be used in this configuration. For application data, contact the supplier of the drive. The DC bus paralleling kit is not supplied with the drive but available to order from the NOTE supplier of the drive.
  • Page 55 On size 6, the power 24 Vdc supply (terminals 51, 52) must be connected to enable the NOTE 24 V dc supply to be used as a backup supply, when the line power supply is removed. If the power 24 Vdc supply is not connected none of the above mentioned functions can be used, "Waiting For Power Systems"...

  • Page 56: Low Voltage Operation

    Figure 4-5 Location of the 24 Vdc power supply connection on size 6 1. 24 Vdc power supply connection Low voltage operation With the addition of a 24 Vdc power supply to supply the control circuits, the drive is able to operate from a low voltage DC supply with a range from 24 Vdc to the maximum DC volts.

  • Page 57: Ratings

    Ratings See section 2.4 Ratings on page 17. Maximum continuous input current The values of maximum continuous input current are given to aid the selection of cables and fuses. These values are stated for the worst case condition with the unusual combination of stiff supply with high imbalance.
  • Page 58 4.9.1 Motor cable types Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 5-24 Maximum motor cable lengths on page 98. Use 105 °C (221 °F) (UL 60/75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power connections: •...
  • Page 59 If it is not practical to use an inverter-rated motor, an output choke (inductor) should be used. The recommended type is a simple iron-cored component with a reactance of about 2 %. The exact value is not critical. This operates in conjunction with the capacitance of the motor cable to increase the rise-time of the motor terminal voltage and prevent excessive electrical stress.

  • Page 60: Braking

     4.9.5 motor operation  The voltage rating for connections of the motor should always be checked before attempting to run the motor. The default setting of the motor rated voltage parameter is the same as the drive rated voltage, i.e. 400 V drive 400 V rated voltage 230 V drive 230 V rated voltage ...
  • Page 61 Table 4-5 shows the default DC voltage level at which the drive turns on the braking transistor. However the braking resistor turn on and the turn off voltages are programmable with Braking IGBT Lower Threshold (06.073) and Braking IGBT Upper Threshold (06.074). Table 4-5 Default braking transistor turn on voltage Drive voltage rating DC bus voltage level...
  • Page 62 Table 4-6 Heatsink mounted braking resistor data Parameter Size 5 Part number 1299-0003 DC resistance at 25 C 37.5  Peak instantaneous power over 1 ms at nominal resistance 16 kW Average power over 60 s * 100 W Ingress Protection (IP) rating IP54 Maximum altitude 2000 m...
  • Page 63 Table 4-7 Minimum resistance values and peak power rating for the braking resistor at 40 °C (104 °F) Instantaneous power Continuous power Minimum resistance * rating rating Model Ω 200 V 05200250 06200330 12.6 16.9 06200440 16.4 400 V 05400270 17.8 16.2 05400300...
  • Page 64 Table 4-8 External brake resistors (40 C ambient) for drive sizes 5 and 6 Cont Max. inst Pulse Pulse Pulse Pulse Ohmic Time Part Part power power power power power power value constant number desc rating rating 1/120 s 5/120 s 10/120 s 40/120 s Pr10.061...
  • Page 65 Table 4-9 Resistor combinations 150 % Braking Resistor Resistor Heavy duty Peak power voltage Min. value combinations Model Ω Ω Ω 1 x 20 = 20 05200250 2 x 40 = 20 (when connected in parallel) 1 x 40 = 40 05400270 11.0 2 x 80 = 40 (when...

  • Page 66: Ground Leakage

    4.10.3 Braking resistor software overload protection The drive software contains an overload protection function for a braking resistor. In order to enable and set-up this function, it is necessary to enter three values into the drive: • Braking Resistor Rated Power (10.030) •...

  • Page 67: Emc (Electromagnetic Compatibility)

    4.11.1 Use of residual current device (RCD) There are three common types of ELCB / RCD: 1. AC - detects AC fault currents 2. A - detects AC and pulsating DC fault currents (provided the DC current reaches zero at least once every half cycle) 3.
  • Page 68 Table 4-10 Drive and EMC filter cross reference Model CT part number 200 V 05200250 4200-0312 06200330 to 06200440 4200-2300 400 V 05400270 to 05400300 4200-0402 06400350 to 06400470 4200-4800 575 V 05500030 to 05500069 4200-0122 06500100 to 06500350 4200-3690 High ground leakage current When an EMC filter is used, a permanent fixed ground connection must be provided which does not pass through a connector or flexible power cord.
  • Page 69 Figure 4-10 Installation of grounding clamp (size 5) Remove the ground connection nuts and slide the grounding clamp down onto the pillars in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft). Unidrive M/HS Frame 5 to 6 Power Installation Guide Issue Number: 9...
  • Page 70 Figure 4-11 Installation of grounding clamp (size 6) The grounding clamp is secured using the provided 2 x M4 x 10 mm fasteners. The fasteners should be tightened with the maximum torque of 2 N m (1.47 Ib ft). Unidrive M/HS Frame 5 to 6 Power Installation Guide Issue Number: 9...
  • Page 71 Figure 4-12 Installation of control grounding bracket (all sizes -size 3 shown) Loosen the ground connection nuts and slide the grounding bracket in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft). A faston tab is located on the grounding bracket for the purpose of connecting the drive 0V to ground should the user require to do so.
  • Page 72 The supply must be disconnected before removing the internal EMC filter. WARNING Figure 4-13 Removal of the size 5 internal EMC filter Remove the three M4 terminal nuts (1). Lift away the cover (2) to expose the M4 Torx internal EMC filter removal screw.
  • Page 73 4.12.3 General requirements for EMC Ground (earth) connections The grounding arrangements should be in accordance with Figure 4-15, which shows a single drive on a back-plate with or without an additional enclosure. Figure 4-15 shows how to configure and minimise EMC when using unshielded motor cable. However shielded cable is a better option, in which case it should be installed as shown in section 4.12.5 Compliance with generic emission standards on page 76.
  • Page 74 Cable layout Figure 4-16 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment. Figure 4-16 Drive cable clearances Optional braking resistor and overload Do not place sensitive (unscreened) signal circuits in a zone extending 300 mm (12”) all around the...
  • Page 75 4.12.4 Compliance with EN 61800-3: 2004+A1:2012 (standard for Power Drive Systems) Meeting the requirements of this standard depends on the environment that the drive is intended to operate in, as follows: Operation in the first environment Observe the guidelines given in section 4.12.5 Compliance with generic emission standards on page 76.
  • Page 76 4.12.5 Compliance with generic emission standards Use the recommended filter and shielded motor cable. Observe the layout rules given in Figure 4-17 and Figure 4-19. Ensure the AC supply and ground cables are at least 100 mm from the power module and motor cable.
  • Page 77 Figure 4-19 Grounding the drive, motor cable shield and filter Ensure direct metal contact at drive and filter mounting points (any paint must be removed). Motor cable shield (unbroken) electrically connected to and held in place by grounding clamp. Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50 mm (2 in) long.
  • Page 78 Figure 4-21 Shielding requirements of optional external braking resistor Optional external braking resistor Optional external braking resistor Enclosure Enclosure If the control wiring is to leave the enclosure, it must be shielded and the shield(s) clamped to the drive using the grounding bracket as shown in Figure 4-22. Remove the outer insulating cover of the cable to ensure the shield(s) make direct contact with the bracket, but keep the shield(s) intact until as close as possible to the terminals.
  • Page 79 4.12.6 Variations in the EMC wiring Interruptions to the motor cable The motor cable should ideally be a single length of shielded or armored cable having no interruptions. In some situations it may be necessary to interrupt the cable, as in the following examples: •...
  • Page 80 Surge immunity of control circuits - long cables and connections outside a building The input/output ports for the control circuits are designed for general use within machines and small systems without any special precautions. These circuits meet the requirements of EN 61000-6-2:2005 (1 kV surge) provided the 0 V connection is not grounded.
  • Page 81 Surge suppression devices are available as rail-mounting modules, e.g. from Phoenix Contact: Unipolar TT-UKK5-D/24 DC Bipolar TT-UKK5-D/24 AC These devices are not suitable for encoder signals or fast digital data networks because the capacitance of the diodes adversely affects the signal. Most encoders have galvanic isolation of the signal circuit from the motor frame, in which case no precautions are required.

  • Page 82: Technical Data

    Technical data Drive technical data 5.1.1 Power and current ratings For a full explanation of ‘Normal Duty’ and ‘Heavy Duty’ refer to the Control User Guide. The continuous current ratings given are for maximum 40 C (104 F), 1000 m altitude and 3 kHz switching frequency.
  • Page 83 Table 5-3 575 V drive ratings (500 V to 575 V ±10 %) Normal Duty Heavy Duty Open Nominal Motor Nominal Motor cont Peak cont loop Model power at power at peak power at power at output current output peak 575 V 575 V current...
  • Page 84 5.1.2 Power and current ratings (Derating for switching frequency and temperature) Table 5-4 Maximum permissible continuous output current @ 40 °C (104 °F) ambient Normal Duty Heavy Duty Maximum permissible continuous output Maximum permissible continuous output Nominal Nominal current (A) for the following switching current (A) for the following switching Model rating...
  • Page 85 Table 5-5 Maximum permissible continuous output current @ 40 °C (104 °F) ambient with high IP insert installed Normal Duty Heavy Duty Maximum permissible continuous output current (A) Maximum permissible continuous output current (A) Model for the following switching frequencies for the following switching frequencies 200 V 05200250...
  • Page 86 Table 5-6 Maximum permissible continuous output current @ 50 °C (122 °F) Normal Duty Heavy Duty Maximum permissible continuous output current (A) Maximum permissible continuous output current (A) Model for the following switching frequencies for the following switching frequencies 200 V 05200250 29.7 25.2...
  • Page 87 5.1.3 Power dissipation Table 5-7 Losses @ 40° C (104° F) ambient Normal Duty Heavy Duty Nominal Drive losses (W) taking into account any Nominal Drive losses (W) taking into account any Model rating current derating for the given conditions rating current derating for the given conditions 200 V...
  • Page 88 Table 5-8 Losses @ 40°C (104° F) ambient with high IP insert installed Normal Duty Heavy Duty Drive losses (W) taking into consideration any current Drive losses (W) taking into consideration any Model derating for the given conditions current derating for the given conditions 200 V 05200250 400 V...
  • Page 89 Table 5-9 Losses @ 50° C (122° F) ambient Normal Duty Heavy Duty Drive losses (W) taking into account any current Drive losses (W) taking into account any current Model derating for the given conditions derating for the given conditions 200 V 05200250 06200330...
  • Page 90 5.1.5 Supply requirements AC supply voltage: 200 V drive: 200 V to 240 V ±10 % 400 V drive: 380 V to 480 V ±10 % 575 V drive: 500 V to 575 V ±10 % Number of phases: 3 Maximum supply imbalance: 2 % negative phase sequence (equivalent to 3 % voltage imbalance between phases).
  • Page 91 Table 5-11 2 % line reactors Line Voltage reactor Drive Inductance Weight Length Width Height Line reactor CT Part rating current model designation number rating number 05200250 INL2008 4401-0226 0.26 3.30 06200330 INL2004 4401-0146 48.8 0.17 06200440 INL2005 4401-0147 56.6 0.15 05400270 INL4013...
  • Page 92 5.1.9 Altitude Altitude range: 0 to 3,000 m (9,900 ft), subject to the following conditions: 1,000 m to 3,000 m (3,300 ft to 9,900 ft) above sea level: de-rate the maximum output current from the specified figure by 1% per 100 m (330 ft) above 1,000 m (3,300 ft) For example at 3,000 m (9,900 ft) the output current of the drive would have to be de-rated by 20 %.
  • Page 93 5.1.11 Corrosive gasses Concentrations of corrosive gases must not exceed the levels given in: • Table A2 of EN 50178:1998 • Class 3C2 of IEC 60721-3-3 This corresponds to the levels typical of urban areas with industrial activities and/or heavy traffic, but not in the immediate neighborhood of industrial sources with chemical emissions.
  • Page 94 5.1.15 Start up time This is the time taken from the moment of applying power to the drive, to the drive being ready to run the motor: Sizes 5 and 6 = 2.5 s For faster start up time a 24V backup supply can be used, see section 4.5 24 Vdc supply on page 54.
  • Page 95 Table 5-14 Acoustic noise data Max ND operation Max HD operation* Min fan speed Size 61.1 56.9 41.9 65.3 55.6 48.2 *At 40 °C ambient and 3 kHz switching frequency. 5.1.19 Overall dimensions Height including surface mounting brackets Width Projection forward of panel when surface mounted Projection forward of panel when through-panel mounted Projection rear of panel when through-panel mounted Table 5-15 Overall drive dimensions...
  • Page 96 Fuses The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Table 5-18, Table 5-19 and Table 5-20 show the recommended fuse ratings. Failure to observe this requirement will cause risk of fire. WARNING Table 5-18 AC Input current and fuse ratings (200 V) Fuse rating Maximum...
  • Page 97 The nominal cable sizes below are only a guide. The mounting and grouping of cables affects their current-carrying capacity, in some cases smaller cables may be acceptable but in other cases a larger cable is required to avoid excessive temperature or voltage drop.
  • Page 98 5.1.22 Maximum motor lengths and types Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 5-24. Use 105 °C (221 °F) (UL 60/75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power connections: •...
  • Page 99 5.1.23 Braking resistor values Table 5-25 Minimum resistance values and peak power rating for the braking resistor at 40 °C (104 °F) Instantaneous power Continuous power Minimum resistance * rating rating Model Ω 200 V 05200250 06200330 12.6 16.9 06200440 16.4 400 V 05400270...
  • Page 100 5.1.24 Torque settings Table 5-26 Drive control and relay terminal data Model Connection type Torque setting Plug-in terminal block 0.5 N m (0.4 lb ft) Table 5-27 Drive power terminal data AC and motor terminals DC and braking Ground terminal Frame size Recommended...
  • Page 101 5.1.25 Electromagnetic compatibility (EMC) This is a summary of the EMC performance of the drive. For full details, refer to the EMC Data Sheet which can be obtained from the supplier of the drive. Table 5-30 Immunity compliance Type of Standard Test specification Application...
  • Page 102 Emission The drive contains an in-built filter for basic emission control. An additional optional external filter provides further reduction of emission. The requirements of the following standards are met, depending on the motor cable length and switching frequency. Table 5-31 Size 5 emission compliance (200 V drives) Switching Frequency (kHz) Motor cable length (m)
  • Page 103 Table 5-34 Size 6 emission compliance (200 V drives) Switching Frequency (kHz) Motor cable length (m) Using internal filter: 0 – 2 Using internal filter and ferrite ring (1 turn – no advantage to 2 turns): 0 – 2 0 – 5 0 –...
  • Page 104 EN 61800-3: 2004+A1:2012 first environment restricted distribution (The following caution is required by EN 61800-3: 2004+A1:2012) This is a product of the restricted distribution class according to IEC 61800-3. In a residential environment this product may cause radio interference in which case the user may be required to take adequate measures.

  • Page 105: Optional External Emc Filters

    Optional external EMC filters Table 5-37 EMC filter cross reference Model CT part number 200 V 05200250 4200-0312 06200330 to 06200440 4200-2300 400 V 05400270 to 05400300 4200-0402 06400350 to 06400470 4200-4800 575 V 05500030 to 05500069 4200-0122 06500100 to 06500350 4200-3690 5.2.1 EMC filter ratings...
  • Page 106 5.2.3 EMC filter torque settings Table 5-40 Optional external EMC Filter terminal data Power Ground connections connections Part number Max cable Max torque Ground stud size Max torque size 2.3 N m 4200-0122 (1.7 lb ft) 5.0 N m 16 mm 4200-0312 (3.7 lb ft) (6 AWG)
  • Page 107 UL listing information UL file reference All drives covered by this manual are UL Listed to both Canadian and US requirements. The UL file reference is: NMMS/7.E171230. Products that incorporate the Safe Torque Off (STO) function are Certified for Functional Safety. The UL file reference is: FSPC.E171230.
  • Page 108 Electrical Installation Overvoltage category Drives have been evaluated for OVC III. Supply The drives are suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 600 Vac Maximum. Terminal Torque Terminals must be tightened to the rated torque as specified in the Installation Instructions. Wiring Terminals Drives must be installed using cables rated for 75 °C operation, copper wire only.
  • Page 109 Requirement for Transient Surge Suppression This requirement only applies to Frame Size 7 drives with rated input voltage = 575 V. TRANSIENT SURGE SUPPRESSION SHALL BE INSTALLED ON THE LINE SIDE OF THIS EQUIPMENT AND SHALL BE RATED 575 Vac (PHASE TO GROUND), 575 Vac (PHASE TO PHASE), SUITABLE FOR OVERVOLTAGE CATEGORY III, AND SHALL PROVIDE PROTECTION FOR A RATED IMPULSE VOLTAGE TO WITHSTAND VOLTAGE PEAK OF 6 kV AND A CLAMPING VOLTAGE OF MAXIMUM 2400 V.
  • Page 110 0478-0255-09...

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