Control Techniques Unidrive Installation Manual
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Control Techniques Unidrive Installation Manual

Low voltage dc
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Installation Guide

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Low Voltage DC
Part Number: 0471-0060-01
Issue Number: 1

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Summary of Contents for Control Techniques Unidrive

  • Page 1: Installation Guide

    www.controltechniques.com Installation Guide Low Voltage DC Part Number: 0471-0060-01 Issue Number: 1...
  • Page 2 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 © October 2005 Control Techniques Drives Ltd Issue Code: 1...

  • Page 3: Table Of Contents

    Component data ............30 Fusing ....................30 Discharge resistor and protection ............32 Brake resistor ..................33 External soft start resistor ..............37 Blocking diode (D1) ................39 Supply capacitor (C1) ................39 Supplier websites ..................40 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...

  • Page 4: Safety Information

    - for example, an over-speed protection device in case of failure of the speed control, or a fail-safe mechanical brake in case of loss of motor braking. Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 5: Environmental Limits

    Environmental limits Instructions in the Unidrive SP User Guide regarding transport, storage, installation and use of the drive must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

  • Page 6: Introduction

    Principles of operation The Unidrive SP is normally operated from a 3-phase AC supply (200V, 400V etc.) or a DC supply of the equivalent rectified voltage. This provides power for all control circuits via the SMPS (Switch Mode Power Supply), and power for the motor via the inverter.

  • Page 7: Operating Modes

    • For Unidrive SP sizes 1 to 6, a 24Vdc supply must be connected to the +24V external input on the green control terminal block of the drive (see Chapter 4 System design ). This supplies the control circuitry and may be connected permanently.
  • Page 8 2.4.2 Operation with a servo motor When in Low Voltage DC operation the Unidrive SP may NOT be able to limit the speed of a servo motor with an overhauling load. WARNING If a permanent magnet motor is made to rotate at a high enough speed by an external torque, the DC bus of the drive and its associated wiring could rise above the lower voltage DC operating level.

  • Page 9: Product Information

    Ratings 3.1.1 Drive output current ratings For drive output current ratings please refer to the Unidrive SP User Guide. 3.1.2 Low Voltage DC rating On all but size 1, the applied Low Voltage DC supply level is set by the user in Pr 6.46.

  • Page 10: Drive Control 24V Rating

    Minimum and maximum voltage values include ripple and noise. Ripple and noise levels must not exceed 5%. A common supply can be used for the drive control 24V and 24V Low Voltage DC mode NOTE enable. Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 11: System Design

    DC bus and trip the drive should it drop below normal operating levels with a charged battery. 2. SM-Applications module used: A software trap should be added to prevent this loop from occurring. Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...

  • Page 12: Low Voltage Dc Supply Types

    The wiring from the fuse to the supply must be rated correctly for the supply. External softstart resistor When Unidrive SP size 1 to 3 operates from AC or DC there is a built in soft start resistor to limit the inrush current. However when Unidrive SP size 4 and larger operate from Low Voltage DC there is no inbuilt soft start resistor and therefore an external soft start resistor is required between the Low Voltage DC supply and the drive.

  • Page 13: Important Considerations And Information

    4.6 System configurations . • Pr 6.44 indicates which supply the drive is currently operating from: 0 = Normal high voltage supply 1 = Low Voltage DC supply. Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...

  • Page 14: System Configurations

    This system configuration is suitable for systems were the power supply cannot absorb any energy from the load through the drive, hence the reason for blocking diode D1 being fitted in series with the DC supply. Figure 4-1 System configuration 1 circuit diagram for Unidrive SP size 1 to 3 Aux.1 Ovld.1...
  • Page 15 Figure 4-2 Control circuitry for system configuration 1 Key: Enable Drive input enable Timer Coil, Delay ON Relay Coil AC Supply select Normally Open Contacts Normally Closed Contacts Aux.1 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 16 Figure 4-3 System configuration 1 circuit diagram for Unidrive SP size 4 to 6, SPMA/D 3-phase AC supply Drive terminals Aux.1 RLY1 Ovld.1 Rdis Control + 24V external input T1 T2 24V Low voltage DC mode enable (T51) 0V (T50) See Chapter 5 Component data on page 30 for details on components.
  • Page 17 Figure 4-4 Control relays for system configuration 1 Key: Enable Drive Timer Coil, Delay ON input enable Relay Coil AC Supply select Normally Open Contacts Normally Closed Contacts Aux.1 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 18 If the above recommendations are unsuccesfull and the drive still trips OV, then it is likely NOTE that the regen energy is significant enough to require a braking resistor. If this is the case refer to section 4.6.5 System configuration 2 on page 20. Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...
  • Page 19 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...

  • Page 20: System Configuration

    Low Voltage DC and AC supplies are both tripped off. As shown in Figure 4-6 Control circuitry for system configuration 2 on page 21 Figure 4-5 System configuration 2 circuit diagram for Unidrive SP size 1 to 3 Aux.3 R_norm Ovld.3...
  • Page 21 Figure 4-6 Control circuitry for system configuration 2 Key: Enable Drive input enable Timer Coil, Delay ON Relay Coil AC Supply select Normally Open Contacts Aux.2 Aux.3 Normally Closed Contacts Aux.1 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 22 Figure 4-7 System configuration 2 circuit diagram for Unidrive SP size 4 to 6, SPMA/D 3-phase AC supply Drive terminals Aux.1 RLY1 Ovld.1 Rdis Control + 24V external input T1 T2 Aux.3 R_norm Ovld.3 Aux.2 Brake R_LVDC Ovld.2 24V Low voltage DC...
  • Page 23 Figure 4-8 Control relays for system configuration 2 Key: Enable Drive Timer Coil, Delay ON input enable Relay Coil AC Supply select Normally Open Contacts Normally Closed Contacts Aux.2 Aux.3 Aux.1 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...

  • Page 24: Power Circuit Control Logic And Sequencing

    Logic OR gate Logic AND gate Logic NOR gate *Supply loss detection signal could also be the output of a supply selector switch (Low Voltage DC or nominal AC supply). Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...
  • Page 25 CONTACTOR OPEN CONTACTOR CONTACTOR CLOSED DISCHARGE RESISTOR CONTACTOR OPEN DRIVE ENABLE PROVIDED DRIVE ENABLE SIGNAL DRIVE ENABLE REMOVED Both delays t1 & t2 should have a minimum value of 1s. Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 26 Both delays t1 & t2 should have a minimum value of 1s. The SM-Applications program should be based on the above sequencing, controlling two of the drive’s digital outputs depending on the state of the AC supply select digital input. Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 27: External Soft Start Circuit Control

    As discussed in section 4.4 External softstart resistor on page 12 an external soft start resistor is required for Unidrive SP size 4 and larger. The soft start resistor only needs to be in circuit at certain times as shown in the flow diagram below.
  • Page 28 Low voltage DC supply Active supply Pr 6.44 Normal high voltage UV trip Under voltage active Pr 10.16 Drive Healthy Contact closed Relay coil Contact open Enable Drive enable Disable 2.5s Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 29: Running The Motor

    Running the motor For information on tuning of the drive for best performance please refer to the Running the motor and optimization section of the Unidrive SP User Guide. Ensure that no damage or safety hazard could arise from the motor starting unexpectedly.

  • Page 30: Component Data

    Component data Fusing Table 5-1 Recommended Low Voltage DC supply fuse current ratings (Unidrive SP size 1 to 3) The fuse voltage rating must be suitable for the rectified drive AC supply voltage, e.g. ≥400Vdc for a SPx20x, ≥750Vdc for a SPx40x, ≥890Vdc for a SPx50x, and ≥1000Vdc for a SPx60x...
  • Page 31 Table 5-2 Recommended Low Voltage DC supply fuse current ratings (Unidrive SP size 4 to 6, SPMA/D) The fuse voltage rating must be suitable for the rectified drive AC supply voltage, e.g. ≥400Vdc for a SPx20x, ≥750Vdc for a SPx40x, ≥890Vdc for a SPx50x, and ≥1000Vdc for a SPx60x...

  • Page 32: Discharge Resistor And Protection

    *The chosen thermal overload relay must have a class 10 trip characteristic. High temperatures The discharge resistor can reach high temperatures. Locate the resistors so that damage cannot result. Use cable having insulation capable of withstanding high temperatures. WARNING Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 33: Brake Resistor

    Please refer to the Unidrive SP User Guide for normal operation brake resistor values. The table below shows the R_LVDC value resistor that is to be fitted in parallel with the normal operation brake resistor.
  • Page 34 Table 5-5 Brake resistor values (R_LVDC) Unidrive SPMA/D Pr 6.46 Average Average Average Average Average Peak Peak Peak Peak Peak power power power power power Drive power power power power power (Ω) over 60s (Ω) over 60s (Ω) over 60s (Ω)
  • Page 35 780V Peak current over the braking period = Peak power at beginning of brake period (W) peak ------------------------------------------------------------------------------------------------------------------------------ - Brake resistor value (Ω ) 135W --------------- - 4.4A 6.9Ω Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 36 If the overload factor (F) is more than 17 times the current setting of the thermal overload NOTE relay, then an in-line fuse would need to be considered. In this case refer to the thermal overload relay manufacturers recommendations. Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 37: External Soft Start Resistor

    An alternative to the fuses recommended in Table 5-7 can be used providing the fuse time vs current characteristic lies between the curves shown in the graphs below and the voltage rating is as per the value shown in Table 5-7. Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 38 Figure 5-2 200V drive time vs current fuse characteristic specification 1000 0.01 0.01 current (Arms) Figure 5-3 400V drive time vs current fuse characteristic specification 1000 0.01 0.01 current (Arms) Unidrive SP Low Voltage DC Installation Guide www.controltechniques.com Issue Number: 1...

  • Page 39: Blocking Diode (D1)

    Voltage rating type (nF) ≥250 Metalised polyester This capacitor is only required with the Unidrive SP size 1. The capacitor should be NOTE connected directly to the drive terminals. Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...

  • Page 40: Supplier Websites

    Supplier websites This capacitor is only required with the Unidrive SP size 1. The capacitor should be NOTE connected directly to the drive terminals. Resistors • www.pentagonelectric.co.uk • www.cressall.com • www.reo.co.uk Contactors and thermal overload relays • www.telemecanique.com • www.abb.com •...

  • Page 41: Unidrive Sp Low Voltage Dc Installation Guide Issue Number

    Preventing over-voltage trips ..............18 Required connections for low voltage DC operation ........11 Running the motor ..................29 Safety of personnel ..................4 Secure disable ....................4 Supplier websites ..................40 System configuration ..............14, 16, 20, 22 Unidrive SP Low Voltage DC Installation Guide Issue Number: 1 www.controltechniques.com...
  • Page 42 0471-0060-01...

This manual is also suitable for:

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