Control Techniques Unidrive UNI1401, 1402, 1403, 1404, 1405, UNI2401, 2402, 2403, UNI3401, 3402, 3403, 3404, 3405, UNI4401, 4402, 4403, 4404, 4405 Control Techniques Unidrive VTC & LFT Presented by - MRO Electric and Supply Company, Inc. For Product Needs: Email: sales@MROELECTRIC.COM Call: 1-800-691-8511 Fax: 919-415-1614 http://www.MROELECTRIC.com/ Control Techniques Unidrive MRO ELECTRIC & SUPPLY Company www.mroelectric.com Installation Guide Unidrive Unidrive VTC Unidrive LFT model sizes 1 to 4 Universal Variable Speed Drive for induction and servo motors 0.75kW to 110kW (1HP to 125HP) Part Number: 0447–0088 Issue Number: 5 Contents Appendix Chapter 1 Safety Information 1-1 A Motor information A-1 1.1 Warnings, Cautions and Notes 1-1 A.1 Cable length A-1 A.2 Multiple motors A-1 1.2 Electrical safety – general warning 1-1 1.3 System design 1-1 B UL listing Information B-1 1.4 Environmental limits 1-1 C Data C-1 1.5 Compliance with regulations 1-1 C.1 Drive C-1 1.6 Safety of personnel 1-1 C.2 Optional RFI filters C-8 1.7 Risk analysis 1-2 1.8 Motor 1-2 1.9 Adjusting parameters 1-2 2 Installing the Drive 2-1 2.1 Environmental requirements 2-1 2.2 EMC considerations 2-2 2.3 Planning the installation 2-3 2.4 Calculating the enclosure size 2-15 2.5 Installing the Drive and RFI filter 2-17 2.6 Power connections 2-31 2.7 Wiring recommendations 2-34 2.8 Variations in the EMC wiring recommendations 2-40 2.9 Signal connections 2-41 Unidrive model sizes 1 to 4 Installation Guide i Issue code: udiu5 A.2 Multiple motors A Motor Connections Open-loop only If the Drive is to control more than one motor, make A.1 Cable length connections as shown in Figure A–1. The maximum cable lengths given in the table in Chapter 2 Installing It is not recommended that a Drive is operated with the Drive apply to the total length of cable from the a motor-cable length greater than that specified in Drive to the farthest motor. the table in Planning the installation in Chapter 2. If this is unavoidable, it is recommended that a It is recommended that each motor is connected sinusoidal filter is used to prevent the PWM switching through a protection relay since the Drive cannot components from entering the motor cable. protect each motor. For star connection, a Sinusoidal filters are available from specialist filter sinusoidal filter or an output inductor must be suppliers. connected as shown in Figure A–1, even when the cable lengths are less than the maximum permissible. For details, of inductor sizes refer to a Drive Centre or distributor listed at the end of the User Guide. Motor protection relay Chain connection (preferred) Star connection Inductor Figure A–1 Connecting motors in parallel Unidrive model sizes 1 to 4 Installation Guide Motor connections A-1 Issue code: udiu5 www.mroelectric.com Table B–1 Maximum continuous output B UL Listing Information current for standard and VTC models The Drive conforms to UL listing requirements only Model FLC (A) when the following are observed: UNI 1401 2.1 • The Drive is installed in a type 1 enclosure, or UNI 1402 2.8 better, as defined by UL50 UNI 1403 3.8 • UL-listed fuses class RK1 600VAC are used in UNI 1404 5.6 the AC supply UNI 1405 9.5 • Class 1 60/75°C (140/167°F) copper wire only is used in the installation UNI 2401 12 • The ambient temperature does not exceed UNI 2402 16 40°C (104°F) when the Drive is operating UNI 2403 25 • The terminal tightening torques specified in UNI 3401 34 the table in Terminal sizes and tightening UNI 3402 40 torques in Chapter 2 Installing the Drive are used UNI 3403 46 UNI 3404 60 B.1 AC supply specification UNI 3405 70 UNI 4401 96 The Drive is suitable for use in a circuit capable of UNI 4402 124 delivering not more than 5000 RMS symmetrical Amperes (10 000 RMS symmetrical Amperes for UNI 4403 156 model size 4) at 528VAC RMS maximum. UNI 4404 180 UNI 4405 202 B.2 Maximum continuous Table B–2 Maximum continuous output output current current for LFT models The Drive models are listed as having the maximum Model FLC (A) continuous output currents (FLC) shown in Tables UNI 1401 LFT 2.1 B–1 and B–2 (see Appendix C Data for details). UNI 1402 LFT 2.8 UNI 1403 LFT 3.8 UNI 1404 LFT 4.0 UNI 1405 LFT 4.3 UNI 2401 LFT 12.0 UNI 2402 LFT 14.2 UNI 2403 LFT 14.2 UNI 3401 LFT 28.0 UNI 3402 LFT 28.0 UNI 3403 LFT 32.0 UNI 3404 LFT 33.0 UNI 3405 LFT 35.0 UNI 4401 LFT 70 UNI 4402 LFT 70 UNI 4403 LFT 80 UNI 4404 LFT 100 UNI 4405 LFT 100 Unidrive model sizes 1 to 4 Installation Guide UL listing B-1 Issue code: udiu5 www.mroelectric.com C Data C.1 Drive Power and current ratings Unidrive and Unidrive VTC (at 40° °C ambient temperature) Model Nominal Maximum permissible Nominal AC rating continuous output current supply current 380V 460V 3kHz 4.5kHz 6kHz 9kHz 12kHz UNI 1401 0.75 kW 1.0 HP 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A 3.1 A UNI 1402 1.1 kW 1.5 HP 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A 3.2 A UNI 1403 1.5 kW 2.0 HP 3.8 A 3.8 A 3.8 A 3.8 A 3.8 A 5.5 A UNI 1404 2.2 kW 3.0 HP 5.6 A 5.6 A 5.6 A 5.6 A 4.5 A 8.4 A UNI 1405 4.0 kW 5.0 HP 9.5 A 9.5 A 8.5 A 7.0 A 5.5 A 9.5 A UNI 2401 5.5 kW 7.5 HP 12.0 A 12.0 A 12.0 A 12.0 A 11.7 A 13.7 A UNI 2402 7.5 kW 10 HP 16.0 A 16.0 A 16.0 A 14.2 A 11.7 A 16.3 A UNI 2403 11.0 kW 15 HP 25.0 A 21.7 A 18.2 A 14.2 A 11.7 A 24.3 A UNI 3401 15.0 kW 25 HP 34.0 A 34.0 A 34.0 A 28.0 A 23.0 A 34.0 A UNI 3402 18.5 kW 30 HP 40.0 A 40.0 A 37.0 A 28.0 A 23.0 A 39.0 A UNI 3403 22.0 kW 30 HP 46.0 A 46.0 A 40.0 A 32.0 A 26.6 A 46.0 A UNI 3404 30.0 kW 40 HP 60.0 A 47.0 A 40.0 A 32.0 A 26.7 A 59.0 A UNI 3405 37.0 kW 50 HP 70.0 A 56.0 A 46.0 A 35.0 A 28.0 A 74.0 A UNI 4401 45 kW 75 HP 96 A 96 A 88 A 70 A 96 A UNI 4402 55 kW 100 HP 124 A 104 A 88 A 70 A 120 A UNI 4403 75 kW 125 HP 156 A 124 A 105 A 80 A 151 A UNI 4404 90 kW 150 HP 180 A 175 A 145 A 110 A 173 A UNI 4405 110 kW 150 HP 202 A 175 A 145 A 110 A 190 A Unidrive model sizes 1 to 4 Installation Guide Data C-1 Issue code: udiu5 www.mroelectric.com 1.4 Environmental limits 1 Safety Information Instructions in this Installation Guide regarding transport, storage, installation and use of Drives must be complied with, including the specified environmental limits. Drives must not be subjected 1.1 to excessive physical force. Warnings, Cautions and Notes 1.5 Compliance with A Warning contains information which is essential regulations for avoiding a safety hazard. The installer is responsible for complying with all A Caution contains information which is necessary relevant regulations, such as national wiring for avoiding a risk of damage to the product or regulations, accident prevention regulations and other equipment. electromagnetic compatibility (EMC) regulations. Particular attention must be given to the A Note contains information which helps to ensure cross-sectional areas of conductors, the selection of correct operation of the product. fuses or other protection, and protective earth (ground) connections. 1.2 Electrical safety – This Installation Guide contains instructions for general warning achieving compliance with specific EMC standards. Within the European Union, all machinery in which The voltages used in the Drive can cause severe this product is used must comply with the following electric shock and/or burns, and could be lethal. directives: Extreme care is necessary at all times when working with or adjacent to the Drive. 89/392/EEC: Safety of Machinery 89/336/EEC: Electromagnetic Compatibility. Specific warnings are given at the relevant places in this Installation Guide and the accompanying User Guide. 1.6 Safety of personnel The installation must comply with all relevant safety legislation in the country of use. The STOP function of the Drive does not remove dangerous voltages from the output of the Drive or from any external option unit. 1.3 System design The Stop and Start controls or electrical inputs of the Drive should not be relied upon to ensure safety The Drive is intended as a component for of personnel. If a safety hazard could exist from professional incorporation into complete equipment unexpected starting of the Drive, an interlock that or systems. If installed incorrectly the Drive may electrically isolates the Drive from the AC supply present a safety hazard. The Drive uses high should be installed to prevent the motor being voltages and currents, carries a high level of stored inadvertently started. electrical energy, and is used to control mechanical equipment which can cause injury. Careful consideration must be given to the functions of the Drive which might result in a Close attention is required to the electrical hazard, either through their intended functions installation and the system-design to avoid hazards (eg. Auto-start) or through incorrect operation due either in normal operation or in the event of to a fault or trip (eg. stop/start, forward/reverse, equipment malfunction. System-design, maximum speed). installation, commissioning and maintenance must be carried out by personnel who have the necessary Under certain conditions, the Drive can suddenly training and experience. They must read this safety discontinue control of the motor. If the load on the information and this Installation Guide carefully. motor could cause the motor speed to be increased (eg. hoists and cranes), a separate method of To ensure mechanical safety, additional safety braking and stopping the motor should be used (eg. devices such as electro-mechanical interlocks may a mechanical brake). be required. The Drive must not be used in a safety- critical application without additional high-integrity protection against hazards arising from a malfunction. Unidrive model sizes 1 to 4 Installation Guide Safety Information 1-1 Issue code: udiu5 www.mroelectric.com 2 Installing the Drive Authorized access The enclosure should prevent Warning access by anyone except for Adhere to the instructions authorized, trained service personnel. The mechanical and electrical Warning installation instructions must be Fire enclosure adhered to. Any questions or doubt should be referred to the The Drive case is not classified supplier of the equipment. It is Warning as a fire enclosure. When this the responsibility of the owner protection is required, the or user to ensure that the Drive should be installed in a installation of the Drive and any fire enclosure. external option unit, and the way in which they are operated and Hazardous areas maintained, comply with the requirements of the Health and The Drive must not be located Warning Safety at Work Act in the United in a classified hazardous area Kingdom or applicable unless the Drive is installed in legislation and regulations and an approved enclosure and the codes of practice in the country installation is certified. in which the equipment is used. Before a Drive is used in the Competence of the installer fully sinusoidal Regeneration mode, the Drive and the The Drive must be installed only accompanying motoring Warning Warning by professional assemblers who Drive(s) must be modified. are familiar with the Contact the supplier of the requirements for safety and EMC. Drive for details. The assembler is responsible for ensuring that the end-product or 1. Refer to Appendix C Data for details of the system complies with all the environmental requirements. relevant laws in the country where it is to be used. 2. If condensation is likely to occur when the Drive is not in use, an anti-condensation heater must be installed. This heater must be switched off Note when the Drive is in use; automatic switching is recommended. Unless otherwise stated, instructions and information in this Installation Guide relate 3. If the Drive is to be mounted directly above any to all versions of the Unidrive. heat-generating equipment (such as another Drive), the maximum temperature of the air immediately below the Drive should be taken as 2.1 Environmental the ambient temperature for the Drive. requirements 4. If the Drive is to be mounted beneath other equipment, such as another Drive, the Drive should not cause the ambient temperature Installation in an enclosure requirements of the equipment to be exceeded. The Drive must be protected Warning 5. When compliance with EMC emission standards against water, condensation and is required, the enclosure must be made of electrically conductive metal but does not require special EMC contamination. When the gland features. plate and appropriate glands are fitted, the Drive can attain UL-listing requirements are given in Appendix B. ingress protection to NEMA 1 and IP40 (in accordance with IEC529). UL listing is valid when the Drive is installed in a type 1 enclosure as defined in UL 50. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-1 Issue code: udiu5 www.mroelectric.com The second environment 2.2 EMC considerations typically includes an industrial low-voltage power supply Depending on the requirements of the installation, network which does not supply one of the following levels of electromagnetic Caution buildings used for domestic compatibility (EMC) should be adopted: purposes. Operating the Drive in this environment without an Routine EMC precautions RFI filter may cause These precautions are recommended when interference to nearby strict compliance with emission standards is not electronic equipment whose required. The risk of disturbing adjacent sensitivity has not been electronic equipment is minimized by adopting appreciated. The user must these precautions. take remedial measures if this situation arises. If the Compliance with EMC emission consequences of unexpected standards disturbances are severe, it is These precautions are recommended when recommended that the strict compliance with emission standards is emission limits of EN50081-2 be required. In addition, it is recommended that adhered to. these precautions are taken when the Drive is installed in a residential area, or adjacent to Instructions are given later in this chapter for these sensitive electronic equipment such as radio levels of EMC. Refer to Appendix C Data for further receivers or similar. information on compliance with EMC standards and definitions of environments. Compliance with EN61800-3 (standard for Power Drive Systems) Detailed instructions and EMC information are given in the Unidrive EMC Data Sheet which is available from Meeting the requirements of this standard the Drive Centres and distributors listed at the end depends on the environment that the Drive is of the User Guide. intended to operate in, as follows: Operation in the first environment Compliance data is given in Appendix C Data. Observe the guidelines given in Compliance with EMC emission standards. An RFI filter will always Note be required. Some model sizes may require additional filtering techniques to be applied. The installer of the Drive is responsible for ensuring compliance with the EMC Operation in the second environment regulations that apply where the Drive is to An RFI filter may not be required. Follow the be used. guidelines given in Routine EMC precautions or The Drive will comply with the standards Compliance with EMC emission standards for emission, such as EN50081–2, only when depending on the requirements of the end user. the instructions given in Planning the installation and Wiring recommendations later in this chapter are followed closely. Unidrive model sizes 1 to 4 Installation Guide 2-2 Installing the Drive Issue code: udiu5 www.mroelectric.com Table 2–1 Fuse ratings for all versions of 2.3 Planning the installation the Unidrive Instructions in numbered steps Model Fuse rating Model Fuse rating UNI 1401 6A UNI 3401 40A The instructions in this section are contained in numbered steps. In some of these steps you will UNI 1402 10A UNI 3402 50A need to make a note of a value for future reference UNI 1403 10A UNI 3403 60A and, to help with identification, the number of the UNI 1404 10A UNI 3404 70A step. UNI 1405 16A UNI 3405 80A AC supply protection UNI 2401 16A UNI 4401 100A UNI 2402 20A UNI 4402 125A The AC supply to the Drive must UNI 2403 35A UNI 4403 160A be fitted with suitable UNI 4404 200A protection against overload Warning and short-circuits. Table 2–1 UNI 4405 250A shows recommended fuse ratings. Failure to observe this Power cables recommendation will cause a risk of fire. Wiring must be in accordance STEP 1 Include a fuse of the specified rating in with local regulations and AC supply. The use of the codes of practice. The table each phase of the Warning below shows typical cable sizes following types of fuse is recommended: for power input and output • Europe: Type gG HRC industrial fuses to wiring. In the event of a IEC 269 (BS88) conflict, local regulations • USA: RK1 600VAC prevail. An MCB or MCCB having the correct thermal and magnetic trip ratings may be used in place Cable type and size of fuses, on condition the fault-current clearing STEP 2 For the following power connections... capacity is sufficient for the installation. • AC supply to RFI filter (when used) Note • AC supply (or RFI filter) to Drive • Drive to motor UL listing is dependent on the use of the • Drive to braking resistor correct type of UL-listed fuse, and applies when the symmetrical short-circuit current ... use 105°C (221°F) pvc-insulated cable of does not exceed 5kA for model sizes 1 to 3, suitable voltage rating and having copper and 10kA for model size 4. Refer to conductors, as shown in Table 2–2. Appendix B UL Listing Information. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-3 Issue code: udiu5 www.mroelectric.com Table 2–2 Cable sizes for all versions of Table 2–3 Maximum cable lengths for all the Unidrive versions of the Unidrive Model Cable size Nominal AC 400V 480V supply 2 UNI 1401 1.5 mm 16 AWG voltage 2 UNI 1402 2.5 mm 14 AWG 2 Model Maximum cable length * UNI 1403 2.5 mm 14 AWG (PWM switching frequency at 3kHz) 2 UNI 1404 2.5 mm 14 AWG mft m ft 2 UNI 1405 2.5 mm 14 AWG UNI 1401 65 210 50 160 2 UNI 2401 2.5 mm 14 AWG 2 UNI 1402 100 330 75 250 UNI 2402 4 mm 10 AWG 2 UNI 1403 130 430 100 330 UNI 2403 4 mm 10 AWG 2 UNI 1404 200 660 150 490 UNI 3401 6 mm 8 AWG 2 UNI 1405 300 990 250 820 UNI 3402 10 mm 6 AWG 2 UNI 3403 10 mm 6 AWG UNI 2401 ~ 300 990 300 990 2 UNI 2403 UNI 3404 16 mm 4 AWG 2 UNI 3401 ~ 200 660 120 410 UNI 3405 25 mm 4 AWG UNI 3405 2 UNI 4401 35 mm 2 AWG 2 UNI 4401 ~ 200 660 120 410 UNI 4402 35 mm 2 AWG UNI 4405 2 UNI 4403 50 mm 0 AWG 2 * Cable lengths in excess of the specified values may be UNI 4404 70 mm 2/0 AWG used only when special techniques are adopted; refer to 2 UNI 4405 95 mm 3/0 AWG the supplier of the Drive. When EMC emission requirements are to be The maximum cable length is reduced from that met, shielded cable or steel wire armoured shown in the table under the following cable may be required for the following: conditions: • AC supply to enclosure • PWM switching frequency exceeding • Drive to motor 3kHz in model sizes 3 and 4 • Drive to braking resistor when part of the The maximum cable length is reduced in cable is outside the enclosure proportion to the increase in PWM switching frequency, eg. at 9kHz, the maximum length For further details, see Wiring guidelines later in this 1 is / of that shown. 3 chapter. • High-capacitance cables Most cables have an insulating jacket between the cores Motor cable and the armour or shield; these cables have a low capacitance and are recommended. STEP 3 Since capacitance in the motor cable Cables that do not have an insulating jacket causes loading on the output of the Drive, tend to have high capacitance; if a cable of ensure the cable length does not exceed the this type is used, the maximum cable length values given in Table 2–3. is half that quoted in the table. (Figure 2–1 shows how to identify the two types.) Normal capacitance High capacitance Shield or armour Shield or armour close separated from the cores to the cores Figure 2–1 Cable construction influencing the capacitance Unidrive model sizes 1 to 4 Installation Guide 2-4 Installing the Drive Issue code: udiu5 www.mroelectric.com The Drive has two forms of thermal protection for Multiple motors the power output stage (IGBT bridge), as follows: Special requirements apply when the Drive is to control more than one motor. Refer to 1. A thermistor mounted on the heatsink monitors Appendix A Motor Connections. the heatsink temperature. If this exceeds 95°C (203°F), the thermistor will cause the Drive to Isolator switch in the motor cable trip. The display will indicate Oh2. An isolator switch may be connected in the 2. Intelligent thermal modelling estimates (by motor cable for safety purposes. Refer to the calculation) the junction temperature of the following Warning and Note. IGBTs. There are two temperature thresholds which cause the following to occur: The isolator switch must not be • If the first threshold is reached, the PWM operated when the Drive is switching frequency is halved in order to enabled. (If an AC-rated switch reduce dissipation in the IGBTs. (When the is used and the Drive is Warning frequency is halved, the value of parameter producing a low output 0.41 PWM switching frequency remains at the frequency when the switch is value set by the user; if the frequency is 3kHz opened, severe arcing can occur or 4.5kHz, no halving occurs). Then at one which will prevent the switch second intervals, the Drive will attempt to from breaking the circuit.) restore the original PWM switching A suitable interlock frequency. This will be successful if the arrangement can be used, such estimated temperature has reduced as an isolator switch fitted sufficiently. with additional contacts that • If the estimated temperature has continued open before the main contacts. to rise and reaches a second threshold, the These additional contacts Drive will trip. The display will indicate Oh1. should be used to disable the Drive. STEP 4 Note that the Drive can deliver an overload current, as shown in Table 2–4. Table 2–4 Overload current Note Unidrive If the isolator switch is closed when the Drive is enabled, the Drive may trip. Open-loop Up to 150% of the rated current for 60 seconds When EMC compliance is required, refer to Variations Closed-loop Vector in the EMC wiring recommendations later in this Up to 175% of the rated current for 60 seconds chapter. Closed-loop Servo Output current, Up to 175% of the rated current for 4 seconds PWM switching frequency, Unidrive VTC Ambient temperature For a variable-torque load Thermal protection Up to 120% of the rated current for 60 seconds Unidrive LFT operating on Note standard S4/S5 duty cycle Open-loop The Drive can supply the rated current up o to an ambient temperature of 40 C (104° °F) Up to 150% of the rated current (depending on the PWM switching frequency Closed-loop Vector used). Up to 175% of the rated current The Drive can be operated in an ambient Closed-loop Servo o o temperature up to 50 C (122 F) at de-rated Up to 175% of the rated current output current. In this case, ensure the value of parameter 0.46 Motor rated current does not exceed the value given in Table 2-5. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-5 Issue code: udiu5 www.mroelectric.com Unidrive LFT Refer to Table 2–6 to find the Frequency / speed maximum continuous output current that can 50Hz be obtained for the ambient temperature for a 1500 RPM standard S4/S5 duty-cycle or for continuous operation. Refer to a Drive Centre or 0 distributor for information on other duty ratios. Current 150% 100% Make a note of this step number and the following: 0 • Unidrive and Unidrive VTC Chosen 2 maximum ambient temperature. 0 20 60 • Unidrive and Unidrive VTC Chosen PWM switching frequency for each Drive. • All Unidrive versions From Table 2–7, Figure 2–2 Standard S4/S5 duty cycle the maximum power dissipation (heat) (Unidrive LFT) figure (P P ) at the chosen PWM switching DISS DISS frequency for each Drive (this figure is the Unidrive and Unidrive VTC Refer to total power dissipation at the maximum Table 2–5 to find the maximum continuous continuous output current available at the output current that can be obtained for the chosen PWM switching frequency, and required ambient temperature and includes power dissipated in option modules PWM switching frequency. The maximum when fitted). Power dissipation in the ambient temperature can be 40°C or 50°C Unidrive LFT is the same as that for the (104°F or 122°F). Note that the nominal power standard Unidrive when operating at 9kHz rating of the Drive may not be achieved above PWM switching frequency. 40°C. • Unidrive and Unidrive VTC If the maximum ambient temperature will be 50°C (122°F), note the value of the maximum Operation in a maximum permissible output current obtained from ambient temperature of 50° °C Table 2–5. This will be the maximum value (122° °F) that parameter 0.46 Motor – rated current Caution should be set at. Unless the precaution described here is taken, the Drive will limit the maximum continuous output current only to the value for 40° °C, and not to the value stated in Table 2–5 for 50° °C. Make a note of the value for 50° °C; you will need to refer to it when you reach Configuring the Drive for the motor in Chapter 3 of the User Guide. At that point, ensure that the value to be entered in parameter 0.46 Motor – rated current does not exceed the noted value. Unidrive model sizes 1 to 4 Installation Guide 2-6 Installing the Drive Issue code: udiu5 www.mroelectric.com Table 2–5 Maximum permissible continuous output current for Unidrive and Unidrive VTC 40° °C (104°F) Nominal Maximum permissible ambient rating continuous output current Model 3kHz 4.5kHz 6kHz 9kHz 12kHz UNI 1401 0.75 kW 1.0 HP 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A UNI 1402 1.1 kW 1.5 HP 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A UNI 1403 1.5 kW 2.0 HP 3.8 A 3.8 A 3.8 A 3.8 A 3.8 A UNI 1404 2.2 kW 3.0 HP 5.6 A 5.6 A 5.6 A 5.6 A 4.5 A UNI 1405 4.0 kW 5.0 HP 9.5 A 9.5 A 8.5 A 7.0 A 5.5 A UNI 2401 5.5 kW 7.5 HP 12.0 A 12.0 A 12.0 A 12.0 A 11.7 A UNI 2402 7.5 kW 10 HP 16.0 A 16.0 A 16.0 A 14.2 A 11.7 A UNI 2403 11.0 kW 15 HP 25.0 A 21.7 A 18.2 A 14.2 A 11.7 A UNI 3401 15.0 kW 20 HP 34.0 A 34.0 A 34.0 A 28.0 A 23.0 A UNI 3402 18.5 kW 25 HP 40.0 A 40.0 A 37.0 A 28.0 A 23.0 A UNI 3403 22.0 kW 30 HP 46.0 A 46.0 A 40.0 A 32.0 A 26.6 A UNI 3404 30.0 kW 40 HP 60.0 A 47.0 A 40.0 A 32.0 A 26.7 A UNI 3405 37.0 kW 50 HP 70.0 A 56.0 A 46.0 A 35.0 A 28.0 A UNI 4401 45 kW 60 HP 96 A 96 A 88 A 70 A UNI 4402 55 kW 75 HP 124 A 104 A 88 A 70 A UNI 4403 75 kW 100 HP 156 A 124 A 105 A 80 A UNI 4404 90 kW 125 HP 180 A 175 A 145 A 110 A UNI 4405 110 kW 125 HP 202 A 175 A 145 A 110 A 50° °C (122°F) Nominal Maximum permissible ambient rating continuous output current Model 3kHz 4.5kHz 6kHz 9kHz 12kHz UNI 1401 0.75 kW 1.0 HP 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A UNI 1402 1.1 kW 1.5 HP 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A UNI 1403 1.5 kW 2.0 HP 3.8 A 3.8 A 3.8 A 3.8 A 3.3 A UNI 1404 2.2 kW 3.0 HP 5.6 A 5.6 A 5.1 A 4.0 A 3.3 A UNI 1405 4.0 kW 5.0 HP 6.9 A 5.9 A 5.1 A 4.0 A 3.3 A UNI 2401 5.5 kW 7.5 HP 12.0 A 12.0 A 12.0 A 11.6 A 9.7 A UNI 2402 7.5 kW 10 HP 16.0 A 16.0 A 14.7 A 11.6 A 9.7 A UNI 2403 11.0 kW 15 HP 20.0 A 17.3 A 14.7 A 11.6 A 9.7 A UNI 3401 15.0 kW 20 HP 34.0 A 34.0 A 28.0 A 21.0 A 17.9 A UNI 3402 18.5 kW 25 HP 40.0 A 34.0 A 28.0 A 21.0 A 17.9 A UNI 3403 22.0 kW 30 HP 44.0 A 36.0 A 31.0 A 24.0 A 20.6 A UNI 3404 30.0 kW 40 HP 44.0 A 36.0 A 31.0 A 24.0 A 20.9 A UNI 3405 37.0 kW 50 HP 50.0 A 41.0 A 34.0 A 26.0 A 23.0 A UNI 4401 45 kW 60 HP 95 A 85 A 75 A 60 A UNI 4402 55 kW 75 HP 105 A 85 A 75 A 60 A UNI 4403 75 kW 100 HP 135 A 105 A 85 A 65 A UNI 4404 90 kW 125 HP 180 A 150 A 125 A 95 A UNI 4405 110 kW 125 HP 190 A 150 A 125 A 95 A Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-7 Issue code: udiu5 www.mroelectric.com Table 2–6 Maximum permissible output current for Unidrive LFT (at 9kHz PWM switching frequency) Model Nominal Maximum permissible output current rating Standard Continuous Continuous duty cycle operation operation at 40° °C at 40°C at 50° °C UNI 1401 LFT 0.75 kW 1.0 HP 2.1 A 2.1 A 2.1 A UNI 1402 LFT 1.1 kW 1.5 HP 2.8 A 2.8 A 2.8 A UNI 1403 LFT 1.5 kW 2.0 HP 3.8 A 3.8 A 3.3 A UNI 1404 LFT 2.2 kW 3.0 HP 5.6 A 4.0 A 3.3 A UNI 1405 LFT 4.0 kW 5.0 HP 9.5 A 4.3 A 3.3 A UNI 2401 LFT 5.5 kW 7.5 HP 12.0 A 12.0 A 11.0 A UNI 2402 LFT 7.5 kW 10 HP 16.0 A 14.2 A 11.0 A UNI 2403 LFT 11.0 kW 15 HP 25.0 A 14.2 A 11.0 A UNI 3401 LFT 15.0 kW 20 HP 34.0 A 28.0 A 21.0 A UNI 3402 LFT 18.5 kW 25 HP 40.0 A 28.0 A 21.0 A UNI 3403 LFT 22.0 kW 30 HP 46.0 A 32.0 A 24.0 A UNI 3404 LFT 30.0 kW 40 HP 60.0 A 33.0 A 24.0 A UNI 3405 LFT 37.0 kW 50 HP 70.0 A 35.0 A 26.0 A UNI 4401 LFT 45 kW 60 HP 96 A 70 A 57 A UNI 4402 LFT 55 kW 75 HP 124 A 70 A 57 A UNI 4403 LFT 75 kW 100 HP 156 A 80 A 61 A UNI 4404 LFT 90 kW 125 HP 180 A 100 A 77 A UNI 4405 LFT 110 kW 125 HP 202 A 100 A 77 A Unidrive model sizes 1 to 4 Installation Guide 2-8 Installing the Drive Issue code: udiu5 www.mroelectric.com Table 2–7 Maximum total power dissipation (Unidrive, Unidrive VTC and Unidrive LFT) Unidrive, Unidrive VTC and Unidrive LFT Model Nominal Maximum total power dissipation rating 3kHz 4.5kHz 6kHz 9kHz 12kHz UNI 1401 0.75kW 1.0HP 80 W 80 W 90 W 90 W 90 W UNI 1402 1.1kW 1.5HP 90 W 90 W 100 W 100 W 110 W UNI 1403 1.5kW 2.0HP 100 W 110 W 110 W 120 W 130 W UNI 1404 2.2kW 3.0HP 130 W 130 W 140 W 150 W 150 W UNI 1405 4.0kW 5.0HP 180 W 190 W 190 W 190 W 170 W UNI 2401 5.5kW 7.5HP 210 W 230 W 250 W 280 W 310 W UNI 2402 7.5kW 10HP 270 W 290 W 310 W 320 W 310 W UNI 2403 11.0kW 15HP 400 W 380 W 360 W 330 W 310 W UNI 3401 15.0kW 20HP 570 W 620 W 670 W 660 W 630 W UNI 3402 18.5kW 25HP 660 W 720 W 730 W 660 W 630 W UNI 3403 22.0kW 30HP 730 W 800 W 770 W 730 W 700 W UNI 3404 30.0kW 40HP 950 W 830 W 790 W 740 W 710 W UNI 3405 37.0kW 50HP 1090 W 990 W 920 W 850 W 800 W UNI 4401 45kW 60HP 1460 W 1610 W 1630 W 1530 W UNI 4402 55kW 75HP 1910 W 1780 W 1670 W 1560 W UNI 4403 75kW 100HP 2370 W 2130 W 2030 W 1860 W UNI 4404 90kW 125HP 2640 W 2890 W 2700 W 2470 W UNI 4405 110kW 125HP 2970 W 2910 W 2720 W 2490 W The default PWM switching frequency is a follows... Unidrive and Unidrive VTC: 3kHz Unidrive LFT: 9kHz Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-9 Issue code: udiu5 www.mroelectric.com Using an RFI filter Using a braking resistor STEP 5 For compliance with the emission Braking occurs when the Drive is decelerating the standards such as EN 50081-1 or EN 50081-2, use motor, or is preventing the motor from gaining the recommended RFI filter as shown in speed due to mechanical influences. During braking, energy is returned to the Drive by the motor. Table 2–8. Use one RFI filter for each Drive. (Standards that are met are specified in When the motor is being braked by the Drive, the Appendix C Data) maximum regenerated power that the Drive can absorb is equal to the power dissipation (losses) of Make a note of this step number and the the Drive. following for each filter to be used: • Size code or part number When the regenerated power is likely to exceed these losses, a braking resistor must be connected. • Maximum power dissipation figure • IP rating By default, the Drive brakes the motor under PI control which extends the deceleration time as necessary in order to keep the DC bus at a constant Table 2–8 RFI filter data voltage. The method of braking can be changed; if Model RFI filter required, refer to Appendix D Menu 0 Parameters in the User Guide. Size Part Maximum IP number power rating dissipation Housing the resistor, and routing the (W) connecting cable UNI 1401 A 4200–0010 25 IP20 A UNI 1402 4200–0010 25 IP20 High temperatures UNI 1403 A 4200–0010 25 IP20 Braking resistors can reach UNI 1404 A 4200–0010 25 IP20 high temperatures. Locate Warning UNI 1405 A 4200–0010 25 IP20 braking resistors so that B damage cannot result. UNI 2401 4200–0027 40 IP20 UNI 2402 B 4200–0027 40 IP20 Use cable having insulation capable of withstanding high UNI 2403 B 4200–0027 40 IP20 temperatures. UNI 3401 C 4200–1051 60 IP00 C UNI 3402 4200–1051 60 IP00 Overload protection UNI 3403 C 4200–1051 60 IP00 It is essential that an overload UNI 3404 D 4200–1071 100 IP00 protection device is Warning incorporated in the braking UNI 3405 D 4200–1071 100 IP00 resistor circuit; this is UNI 4401 E 4200–1111 120 IP00 described in Protection circuit UNI 4402 F 4200–1171 150 IP00 for an optional braking resistor in STEP 8. F UNI 4403 4200–1171 150 IP00 UNI 4404 F 4200–1171 150 IP00 UNI 4405 H 4200–1220 200 IP00 STEP 6 When a braking resistor is to be mounted outside the enclosure, ensure that it is mounted in a ventilated metal housing that will perform Model size 1 the following functions: When the motor cable is to exceed 50m (165 feet), • Prevent inadvertent contact with the use RFI filter size B (4200–0027). resistor • Allow adequate ventilation for the resistor Unidrive model sizes 1 to 4 Installation Guide 2-10 Installing the Drive Issue code: udiu5 www.mroelectric.com When compliance with EMC emission standards Optimization of the braking resistor requires a is required, external connection requires the careful consideration of the braking duty. This is cable to be armoured or shielded, since it is not described more fully in Optimizing an optional braking fully contained in a metal enclosure. resistor in the Unidrive Advanced User Guide. Internal connection does not require the cable STEP 7 Select a value of resistance for the braking to be armoured or shielded. resistor that is not less than the specified minimum resistance. Larger resistance values Minimum resistances and power ratings may give a cost saving, as well as a safety benefit in the event of a fault in the braking system. Braking capability will then be Table 2–9 Minimum resistance values and reduced, which may cause the Drive to trip peak power rating for the during braking. If this occurs, refer to Adjusting braking resistor at 40° °C (104° °F) the deceleration rate in the User Guide. Model Minimum Instantaneous STEP 8 Estimate the average power that will be resistance power rating dissipated in the resistor. A method of UNI 1401 ~ UNI 1405 40Ω 15kW estimating this power is described in Optimizing UNI 2401 40Ω 15kW an optional braking resistor in the Unidrive UNI 2402, UNI 2403 30Ω * 20kW Advanced User Guide. Make a note of this step number and the average power to be dissipated UNI 3401 ~ UNI 3405 10Ω 60kW in the resistor. UNI 4401 ~ UNI 4405 5Ω 120kW Thermal protection circuit for the * For Drives having date code earlier than G50, the braking resistor minimum resistance is 40Ω. The minimum resistance allows the braking resistor The thermal protection circuit must disconnect the to dissipate up to approximately 150% of the power AC supply from the Drive if the resistor becomes rating of the Drive for up to 60 seconds. overloaded. Figure 2–3 shows a typical circuit arrangement. For high-inertia loads or under continuous braking, the continuous power dissipated in the braking resistor may be as high as the power rating of the Drive. The total energy dissipated in the braking Optional resistor is dependent on the amount of energy to be RFI filter extracted from the load. The instantaneous power rating refers to the short-term maximum power dissipated during the on intervals of the pulse width modulated braking control cycle. The braking resistor must be able to Drive Stop withstand this dissipation for short intervals (milliseconds). Higher resistance values require Thermal Start / proportionately lower instantaneous power ratings. Reset protection device In most applications, braking occurs only occasionally. This allows the continuous power rating of the braking resistor to be much lower than the power rating of the Drive. It is essential, Braking resistor though, that the instantaneous power rating and energy rating of the braking resistor are sufficient Figure 2–3 Typical protection circuit for a for the most extreme braking duty that is likely to braking resistor be encountered. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-11 Issue code: udiu5 www.mroelectric.com STEP 11 For compliance with EMC emission Enclosure layout standards, ensure the enclosure is fitted with an unpainted metal back-plate for mounting the STEP 9 Use one of the following enclosure Drive and RFI filter. For example, a zinc plated layouts, depending on the requirements of the steel back-plate is suitable (see Figure 2–5). installation: Routine EMC precautions Refer to TEP 12 Ensure the Drive is installed vertically for S Figure 2–4 which shows the recommended best flow of cooling air through the Drive and layout for two Drives, and the signal and power heatsink. cables. STEP 13 Ensure the clearances around the Drive are Compliance with EMC emission as follows: standards Refer to Figure 2–5 which shows Above and below: ≥100mm (4 in) the recommended layout for two Drives, two 1 RFI filters, and the signal and power cables. Both sides: ≥5mm ( / in) 4 For overall dimensions and weights of the Drive STEP 10 Decide whether the enclosure is to be and RFI filter, see Appendix C Data. sealed or ventilated, as follows: A sealed enclosure can give a high ingress- STEP 14 When compliance with EMC emission protection rating, but with reduced heat standards is required, the RFI filter must be removal capabilities. If possible, locate heat- installed at the specified position for each Drive generating equipment (other than braking (see Figure 2–5). resistors) in the lower part of the enclosure to encourage internal convection. If necessary, a STEP 15 When a braking resistor is to be used, it taller enclosure, and/or air-circulation fans can be installed outside or inside the enclosure. inside the enclosure, can be used. For When installed inside, it must be mounted in calculating the minimum size of sealed the upper part of the enclosure to prevent it enclosure that will adequately cool the Drive(s), heating the other equipment by convection. refer later in this chapter to Calculating the size of a sealed enclosure. If a high ingress-protection rating is not required, a ventilated enclosure can be used with a fan to supply forced air cooling; this can give a lower ambient temperature than a sealed enclosure. For calculating the minimum required volume of cooling air, refer later in this chapter to Calculating the air-flow in a ventilated enclosure. Unidrive model sizes 1 to 4 Installation Guide 2-12 Installing the Drive Issue code: udiu5 www.mroelectric.com Optional braking resistors as required for the Drives External: Mount on top surface of enclosure. Internal: Mount in top part of enclosure. Overload protection device Drives Ensure minimum ≥100mm ≥5mm ≥5mm clearances are (4in) (¼in) (¼in) respected. Back-plate System controller Locate as required. Signal cables Plan for all signal cables to be routed at least 300mm (12in) distant from any power cable. ≥100mm (4in) Location of optional terminal block Power cables Alternative location of AC supply isolator, fuses or contactor, and MCBs fuses or MCBs Locate as Locate as required. required. Enclosure Figure 2–4 Recommended layout for routine EMC precautions (wiring recommendations are given in Figure 2–21) Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-13 Issue code: udiu5 www.mroelectric.com Optional braking resistors as required for the Drives External: Mount on top surface of enclosure. Internal: Mount in top part of enclosure. Overload protection device Alternative location of fuses or MCBs Locate as required. Drives and RFI filters ≥5mm Ensure minimum ≥5mm (¼in) clearances are (¼in) ≥100mm (4in) respected. System controller ≥5mm Locate as required. (¼in) Signal cables Plan for all signal cables to be routed at least 300mm (12in) distant from any power cable. 150mm (6in) RFI filters Install a separate RFI filter for each Drive. Back-plate Power cables Alternative location of Location fuses or MCBs AC supply isolator, of optional Locate as required. contactor, and terminal fuses or MCBs block Locate as required. Enclosure Figure 2–5 Recommended layout for compliance with EMC emission standards (wiring recommendations are given in Figures 2–22 and 2–23) Unidrive model sizes 1 to 4 Installation Guide 2-14 Installing the Drive Issue code: udiu5 www.mroelectric.com P Power in Watts dissipated by all heat 2.4 Calculating the sources in the enclosure enclosure size k Heat transmission coefficient of the 2 enclosure material in W/m /°C STEP 1 Add the dissipation figures from step 4 of Planning the installation for each Drive that is to Example be installed in the enclosure. Make a note of To calculate the size of an enclosure for the this step number and the total value. following: STEP 2 If an RFI filter is to be used with each • Two UNI 1405 models Drive, add the dissipation figures from step 5 of • Each Drive to operate at 4.5kHz PWM Planning the installation for each RFI filter that is switching frequency to be installed in the enclosure. Make a note of • RFI filter for each Drive this step number and the total value. • Braking resistors are to be mounted outside STEP 3 If the braking resistor is to be mounted the enclosure inside the enclosure, add the average power • Maximum ambient temperature inside the figures from step 8 of Planning the installation for enclosure: 40°C each braking resistor that is to be installed in • Maximum ambient temperature outside the the enclosure. Make a note of this step number enclosure: 30°C and the total value. Dissipation of each Drive: 190W (from step 4 in STEP 4 Make a note of this step number and the Planning the installation) total heat dissipation (in Watts) of any other equipment to be installed in the enclosure. Dissipation of each RFI filter: 25W (max) (from step 5 in Planning the installation) STEP 5 Add the heat dissipation figures obtained (as appropriate) from steps 1, 2, 3 and 4 above. Total dissipation: 2 x (190 + 25) = 430W This gives a figure in Watts for the total heat The enclosure is to be made from painted 2mm that will be dissipated inside the enclosure. 3 ( / in) sheet steel having a heat transmission Make a note of this figure and the step number. 32 2 coefficient of 5.5W/m /°C. Only the top, front, and two sides of the enclosure are to be free to Calculating the size of a dissipate heat. sealed enclosure The enclosure transfers internally generated heat into the surrounding air by natural convection (or external forced air flow); the greater the surface area of the enclosure walls, the better is the dissipation capability. Only the surfaces of the enclosure that are unobstructed (not in contact with a wall or floor) can dissipate heat. Calculate the minimum required unobstructed surface area A for the enclosure from: e P A= e k(T - T ) iamb Where: 2 Ae Unobstructed surface area in m 2 2 Figure 2–6 Enclosure having front, sides and (1m = 10.8 ft ) top panels free to dissipate heat T Maximum expected ambient amb temperature in °C outside the enclosure T Maximum permissible ambient i temperature in °C inside the enclosure Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-15 Issue code: udiu5 www.mroelectric.com Insert the following values: Where: 3 T 40°C V Air-flow in m per hour i T 30°C T Maximum ambient temperature in °C amb amb outside the enclosure k 5.5 T Maximum ambient temperature in °C i P 430W inside the enclosure The minimum required heat conducting area is then: P Power in Watts dissipated by all heat sources in the enclosure 430 22 A= = 7.8m (85ft ) e p 5.5(40 - 30) 0 k Ratio of P I (1m = 3.3 ft) Where: P is the air pressure at sea level Estimate two of the enclosure dimensions — the 0 height (H) and depth (D), for instance. Calculate P is the air pressure at the I the width (W) from: installation Typically use a factor of 1.2 to 1.3, to Ae - 2HD W= allow also for pressure-drops in dirty H+D air-filters. Inserting H = 2m and D = 0.6m, obtain the minimum Example width: To calculate the size of an enclosure for the 7.8 - (2×× ×20 × .6) following: W= == 21 . m (6ft 10in) 2 + 0.6 • Three UNI 3401 models • Each Drive to operate at 6kHz PWM switching If the enclosure is too large for the space available, frequency it can be made smaller only by attending to one or all of the following: • RFI filter for each Drive • Braking resistors are to be mounted outside • Using a lower PWM switching frequency to the enclosure reduce the dissipation in the Drives (return to step 4 in Planning the installation) • Maximum ambient temperature inside the enclosure: 40°C • Reducing the ambient temperature outside the enclosure, and/or applying forced-air • Maximum ambient temperature outside the cooling to the outside of the enclosure enclosure: 30°C • Reducing the number of Drives in Dissipation of each Drive: 670W (from step 4 in the enclosure Planning the installation) • Removing other heat-generating equipment Dissipation of each RFI filter: 60W (max) (from step 5 in Planning the installation) Calculating the air-flow in a ventilated enclosure Total dissipation: 3 x (670 + 60) = 2190W The dimensions of the enclosure are required only Insert the following values: for accommodating the equipment. The equipment T 40°C i is cooled by the forced air flow. T 30°C amb Calculate the minimum required volume of k 1.3 ventilating air from: P 2190W 3kP Then: V= T-ia Tmb 32 ××× 13 .×190 33 V= == 854m / hr (504 ft /min) 40 - 30 3 3 (1m /hr = 0.59ft /min) Unidrive model sizes 1 to 4 Installation Guide 2-16 Installing the Drive Issue code: udiu5 www.mroelectric.com 2.5 Installing the Drive and RFI filter Lifting the Drive The weights of model sizes 3 Warning and 4 are 22kg (49 lbs) and 70kg (154 lbs) respectively. Use appropriate safeguards when lifting these models. Removing the terminal covers Figure 2–8 View from the underside showing how a terminal cover is removed The Drive is fitted with one or two terminal covers from the Drive depending on the model size. When model sizes 1, 3 and 4 are through-panel mounted, the terminal cover(s) must first be removed in order for access Remove terminal covers, as follows: to be gained to the lower mounting holes. 1. Working on either side of the terminal cover, push the inner edge of the cover firmly outward until it becomes unclipped. 2. Swing the side of the cover outward and upward until the remaining clips become released. 3. Remove the gland plate (you may need to replace it later). Figure 2–7 Removing the terminal covers The terminal cover(s) of all models must be removed for access to the electrical connectors. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-17 Issue code: udiu5 www.mroelectric.com Mounting brackets supplied Surface-mounting the Drive with the Drive 1. Use the two surface-mounting brackets. These are manufactured from metal. Ensure the brackets make direct electrical contact with the Table 2–10 General views of the 3 back-plate; for example, tap M5 ( / in) mounting brackets 16 threaded holes in the back-plate in the positions Model Through-panel Surface shown in Figure 2–10 to accept the mounting size screws. (For model size 1, you may use the central or, preferably, the two outer screw 1 holes in the mounting bracket.) 2. Insert the surface mounting brackets into the slots in the top and bottom of the Drive heatsink, as shown in Figure 2–9. Upper and lower 2 Upper and lower 3 Upper Figure 2–9 General representation showing the fitting of a surface mounting bracket in a heatsink 3. Retain the mounting brackets to the back-plate using electrically conducting screws. Lower 4 Upper Lower Rear view of the brackets (except for the lower bracket for model size 4). The brackets are not shown to scale. Unidrive model sizes 1 to 4 Installation Guide 2-18 Installing the Drive Issue code: udiu5 www.mroelectric.com This page is intentionally not used Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-19 Issue code: udiu5 www.mroelectric.com Model size 1 Back-plate Model size 2 Back-plate Figure 2–10 Surface mounting of model sizes 1 and 2 Unidrive model sizes 1 to 4 Installation Guide 2-20 Installing the Drive Issue code: udiu5 www.mroelectric.com Model size 3 Back-plate Model size 4 Back-plate Figure 2–11 Surface mounting of model sizes 3 and 4 Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-21 Issue code: udiu5 www.mroelectric.com Back-plate Model size 1 Back-plate Model size 2 Figure 2–12 Through-panel mounting of model sizes 1 and 2 Unidrive model sizes 1 to 4 Installation Guide 2-22 Installing the Drive Issue code: udiu5 www.mroelectric.com Model Back-plate size 3 Model size 4 Back-plate Figure 2–13 Through-panel mounting of model sizes 3 and 4 Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-23 Issue code: udiu5 www.mroelectric.com 4. If a seal is required between the Drive and the Through-panel mounting the Drive back-plate, attach the foam sealing strip (supplied with the Drive) around the edges of 1. Cut an aperture in the back-plate as shown in the aperture in the back-plate so that the flange Figure 2–12 or 2–13 as appropriate. on the heatsink will press against the foam strip. 2. Use the through-panel mounting bracket. This 5. Insert the Drive into the aperture. is manufactured from metal and is used to secure the top of the Drive to the back-plate; 6. Secure the bottom of the Drive to the panel the bottom of the Drive is secured to the back- using electrically conducting screw(s). plate by screw(s) passed through a hole in the casing and heatsink. 7. Secure the through-panel mounting bracket to the panel using electrically conducting screw(s). Ensure the bracket and heatsink make direct electrical contact with the back-plate; for 3 8. If the maximum permissible continuous output example, tap M5 ( / in) threaded holes in the 16 current (from step 4 in Planning the installation) back-plate in the positions shown in Figure 2–12 is required, a baffle plate must be fitted to the or 2–13 to accept the mounting screws. rear of the Drive heatsink. See Fitting a baffle plate later in this chapter. If a baffle plate is not 3. Insert the through-panel mounting bracket into the recess in the top of the Drive heatsink, as fitted, the maximum output current must be shown in Figure 2–14. limited to 80% of the specified value. In this case, adjust the value noted at step 4 in Planning the installation. Fitting a baffle plate If the Drive has been used, the heatsink may be hot. Human contact with the heatsink should be restricted. Warning When the Drive is through-panel mounted, the fitting of a baffle plate causes the heatsink to act as a chimney; this enhances the air flow along the heatsink fins to aid cooling (this naturally occurs when the Drive is surface mounted). You may make a baffle plate from any suitable conducting or non-conducting material and attach it to the heatsink by the method described below. Figure 2–14 General representation showing the fitting of a through-panel mounting bracket in the top of the Drive Unidrive model sizes 1 to 4 Installation Guide 2-24 Installing the Drive Issue code: udiu5 www.mroelectric.com Figure 2–15 Dimensions for the fabrication of baffle plates for model sizes 1 and 2 Attaching a fabricated baffle plate to the heatsink Table 2–12 Methods of attaching the baffle plate Model Method of attachment size 1 Use the surface mounting brackets. 2 Figure 2–16 Dimensions for the fabrication 3 Use M6 x 12mm max (or equivalent) of baffle plates for model 4 thread-forming screws to screw into the holes sizes 3 and 4 in the heatsink, or tap the holes to a suitable thread size. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-25 Issue code: udiu5 www.mroelectric.com This page is intentionally not used Unidrive model sizes 1 to 4 Installation Guide 2-26 Installing the Drive Issue code: udiu5 www.mroelectric.com Mounting the RFI filter The RFI filters can be surface-mounted only. Mount the RFI filter at the specified location in relation to the Drive. In the case of filter sizes C to G, ensure the LOAD terminals face the Drive. Dimension RFI filter size A B 4200–0010 4200–0027 C 378mm 388mm 7 1 14 / in 15 / in 8 4 D 114.5mm 114.5mm 1 1 4 / in 4 / in 2 2 E 335mm 335mm 3 3 13 / in 13 / in 16 16 F 25mm 37.5mm 1 1 in 1 / in 2 G 6.4mm 6.4mm 1 1 / in / in 4 4 H 396mm 406mm 9 15 / in 16 in 16 J 10mm 10mm 3 3 / in / in 8 8 W 50mm 75mm 15 15 1 / in 2 / in 16 16 Figure 2–17 Principal dimensions of RFI filters sizes A and B, and the locations of the terminals Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-27 Issue code: udiu5 www.mroelectric.com Figure 2–18 Principal dimensions of RFI filters sizes C to F, and the locations of the terminals Unidrive model sizes 1 to 4 Installation Guide 2-28 Installing the Drive Issue code: udiu5 www.mroelectric.com Dimension RFI filter size C D E F 4200–1051 4200–1071 4200–1111 4200–1171 A 15mm 15mm 15mm 15mm 9 9 9 9 / in / in / in / in 16 16 16 16 B 160mm 160mm 170mm 170mm 5 5 11 11 6 / in 6 / in 6 / in 6 / in 16 16 16 16 C 305mm 305mm 400mm 400mm 3 3 12 in 12 in 15 / in 15 / in 4 4 D 15mm 15mm 15mm 15mm 9 9 9 9 / in / in / in / in 16 16 16 16 F 12.5mm 12.5mm 20mm 15mm 1 1 3 9 / in / in / in / in 2 2 4 16 G 6.5mm 6.5mm 6.5mm 6.5mm 1 1 1 1 / in / in / in / in 4 4 4 4 H 145mm 145mm 145mm 145mm 11 11 11 11 5 / in 5 / in 5 / in 5 / in 16 16 16 16 J 280mm 280mm 340mm 430mm 3 3 3 15 11 / in 11 / in 13 / in 16 / in 16 16 8 16 K 25mm 25mm 50mm 50mm 15 15 1 in 1 in 1 / in 1 / in 16 16 L 330mm 330mm 440mm 490mm 5 1 13 in 13 in 17 / in 19 / in 16 4 M 35mm 35mm 35mm 20mm 3 3 3 3 1 / in 1 / in 1 / in / in 8 8 8 4 N 60mm 60mm 65mm 80mm 3 3 9 1 2 / in 2 / in 2 / in 3 / in 8 8 16 8 P 45mm 45mm 70mm 50mm 3 3 3 1 / in 1 / in 2 / in 2 in 4 4 4 Q 240mm 240mm 300mm 390mm 7 7 13 3 9 / in 9 / in 11 / in 15 / in 16 16 16 8 S 80mm 80mm 80mm 80mm 1 1 1 1 3 / in 3 / in 3 / in 3 / in 8 8 8 8 T 30mm 30mm 30mm 30mm 3 3 3 3 1 / in 1 / in 1 / in 1 / in 16 16 16 16 U 50mm 50mm 50mm 50mm 2 in 2 in 2 in 2 in V 40mm 40mm 40mm 40mm 9 9 9 9 1 / in 1 / in 1 / in 1 / in 16 16 16 16 W 190mm 190mm 200mm 200mm 1 1 7 7 7 / in 7 / in 7 / in 7 / in 2 2 8 8 X 40mm 40mm 40mm 40mm 9 9 9 9 1 / in 1 / in 1 / in 1 / in 16 16 16 16 Z M5 x 10mm M5 x 10mm M5 x 10mm M5 x 10mm Terminals M8 M8 M10 M10 Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-29 Issue code: udiu5 www.mroelectric.com Figure 2–19 Principal dimensions of RFI filter size H, and the locations of the terminals Unidrive model sizes 1 to 4 Installation Guide 2-30 Installing the Drive Issue code: udiu5 www.mroelectric.com Dimension RFI filter 2.6 Power connections size H Electric shock risk 4200–1220 A 15mm The voltages present in the 9 Warning / in 16 following locations can cause B 170mm severe electric shock and may 11 6 / 16 be lethal: C 560mm 7 AC supply cables and 22 / 16 connections D 15mm 9 Output cables and / in 16 connections F 15mm 9 / in Many internal parts of the 16 G 6.5mm Drive, and external option 1 / 4 units H 145mm 11 5 / 16 Isolation device J 530mm 7 20 / 8 The AC supply must be Warning K 30mm disconnected from the Drive 3 1 / in 16 using an approved isolation L 590mm device before any cover is 1 23 / 4 removed from the Drive or M 20mm before any servicing work is 3 / in 4 performed. N 80mm 1 3 / 8 Stored charge P 50mm 15 1 / 16 The Drive contains capacitors Warning Q 490mm that remain charged to a 5 19 / 16 potentially lethal voltage after S 72.5mm the AC supply has been 7 2 / 8 disconnected. If the Drive has T 20mm been energized, the AC supply 3 / in 4 must be isolated at least U 50mm 15 ten minutes before work may 1 / 16 continue. V 45mm 3 1 / 4 AC supply by plug and socket W 200mm 7 7 / 8 Special attention must be given X 40mm Warning if the Drive is installed in 9 1 / in 16 equipment which is connected to the AC supply by a plug and socket. The AC supply terminals of the Drive are connected to the internal capacitors through rectifier diodes which do not give isolation. If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically isolating the plug from the Drive must be used (eg. a latching relay). Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-31 Issue code: udiu5 www.mroelectric.com Power and ground terminals STOP function The STOP function does not Warning remove dangerous voltages from the Drive or any external option units. Ground leakage current – model sizes 3 and 4 Warning Ground leakage current is typically 9mA*. A fixed ground connection must be made before AC power is applied. In some applications, safety regulations require a duplicate ground connection. * 9mA at 380V ~ 415V 50Hz AC supply; up to 14mA at 480V 60Hz AC supply. Measured by the method described in IEC950 Annex D. Ground connections (earthing, equi-potential bonding) The ground terminal of 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. Refer to Wiring recommendations later in this chapter. The ground loop impedance must conform to the requirements of local safety Warning regulations. The Drive must be grounded by a connection capable of Figure 2–20 Locations of the power and carrying the prospective fault ground terminals current until the protective device (fuse, etc) disconnects the AC supply. Terminal sizes and tightening torques The ground connections must be inspected and tested at appropriate intervals. To avoid a fire hazard and maintain validity of the UL listing, adhere to the specified tightening torques for the Warning power and ground terminals. Refer to the following tables. Unidrive model sizes 1 to 4 Installation Guide 2-32 Installing the Drive Issue code: udiu5 www.mroelectric.com Drive Using the gland plate and cable glands Table 2–13 Mechanical data for the Drive terminals When the gland plate(s) are not fitted, objects less than 60mm Model Power Ground 1 (2 / in) wide can pass through 2 Warning size terminals terminal the cable entry opening and Size Torque Size Torque possibly make contact with live Type Type parts inside the Drive. 1 Plug-in 0.5 N.m M4 3 N.m terminal 4.4 lb.in (Torx/ 2.2 lb.ft Fit the gland plate and cable glands as required. block slot-head Before fitting cable glands, push out sufficient screw) blanking caps from the gland plate. 2 Plug-in 0.5 N.m M4 3 N.m Note that the IP rating of the Drive is reduced if any terminal 4.4 lb.in (Torx/ 2.2 lb.ft block slot-head holes in the gland plate are left open. The rating is screw) affected as follows: 3 M10 stud 15 N.m M10 stud 15 N.m 11 lb.ft 11 lb.ft Gland plate not fitted IP00 4 M10 stud 15 N.m M10 stud 15 N.m Gland plate fitted IP10 11 lb.ft 11 lb.ft Unused holes uncovered Torque tolerance ±10% Gland plate and glands fitted IP40 Blanking caps covering unused holes RFI filter Table 2–15 Diameters of the holes in Table 2–14 Mechanical data for the the gland plate RFI filter terminals Gland plate hole diameter Size Power Ground terminals terminal Model Control signal Power cables size wiring Size Torque Size Torque Type Type 1 20mm 20mm 3 3 A Screw 0.7 N.m Screw 0.7 N.m / in / in 4 4 terminals 6. lb.in terminals 6. lb.in 2 20mm 20mm 3 3 B / in / in M8 stud 1.6 N.m M8 stud 1.6 N.m 4 4 14 lb.in 14 lb.in 3 20mm 28mm 3 1 C M8 stud 12.6 N.m M8 stud 12.6 N.m / in 1 / 4 16 9 lb.ft 9 lb.ft 4 20mm 28mm 3 1 D M8 stud 12.6 N.m M8 stud 12.6 N.m / in 1 / 4 16 9 lb.ft 9 lb.ft E M10 stud 25 N.m M10 stud 25 N.m 18 lb.ft 18 lb.ft F M10 stud 25 N.m M10 stud 25 N.m 18 lb.ft 18 lb.ft H M10 bus- 25 N.m M10 stud 25 N.m bar hole 18 lb.ft 18 lb.ft Torque tolerance ±10% Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-33 Issue code: udiu5 www.mroelectric.com Compliance with EMC emission 2.7 Wiring recommendations standards Observe the wiring recommendations given in this • Strict compliance with emission standards. section. Recommendations are given separately for • When the Drive is installed in a residential the following: area, or adjacent to sensitive electronic equipment such as radio receivers or similar. Routine EMC precautions The details of individual installations may vary, but • Recommended when strict compliance with details which are indicated in the recommendations emission standards is not required. to be important for EMC must be adhered to • Minimized risk of disturbing adjacent closely. electronic equipment. For further details when EMC emission requirements are to be met, refer to the Unidrive EMC Data Sheet for the size of Drive used. Key to symbols Single power cable Optional external Three-core power cable or braking resistor three single power cables Four-core power cable (3-phase + ground) Ground cable No sensitive circuits permitted in this zone Drive Control cables to the Drives Output 3 Output 2 Output 1 _ L1 L2 L3 UVW + 0V Ground Host controller AC supply L1 Isolator Contactor L2 Fuses or MCB L3 Back-plate Ground Power-ground Enclosure bus-bar Figure 2–21 Wiring guidelines for routine EMC precautions (model sizes 1 to 4) Unidrive model sizes 1 to 4 Installation Guide 2-34 Installing the Drive Issue code: udiu5 www.mroelectric.com Routine EMC precautions (model sizes 1 to 4) General features Routine EMC precautions 1. Single power-ground bus-bar, or low- 11 Use four-core cable to connect the motor to impedance ground terminal. the Drive as shown. The ground conductor in the motor cable must be connected only to the 2. Incoming AC supply ground connected to the ground terminals of the Drive and motor; it power ground bus-bar. must not be connected directly to the power- ground bus-bar. 3. Connect grounds of any other circuits to the power ground bus-bar. 12. If the wiring for sensitive signal circuits is to be parallel to an unshielded motor cable (or cables 4. Site ground, if required. for an unfiltered power supply) for more than 1 metre (3 feet), ensure the separation is at 5. Metal back-plate, safety bonded to the power least 0.3m (12 in). ground bus-bar. If the parallel run is to exceed 10 metres (30 6. System isolator, circuit contactors and feet), increase the separation proportionally. fuses/MCB. For example, if the parallel run is to be 40 metres, the spacing must be 0.3 x 40 ÷ 10 = 7. Alternative position for Drive fuses/MCB. 1.2 metres. 8. Motor-frame ground connection, if required. When a motor-thermistor is used, this constraint does not apply to the cable 9. Optional braking resistor mounted externally, connecting the thermistor to the Drive. The protected by a metal grille. motor-thermistor cable must be shielded (as shown in Figures 3–4 and 3–5 in the User Guide). 10. Thermal protection device to protect the braking resistor. 13. Do not place sensitive signal circuits in a zone extending 0.3m (12 in) all around the Drive. 14. If the control circuit 0V is to be grounded, this should be done at the system controller (eg. PLC) and not at the Drive. This is to avoid injecting noise currents into the 0V circuit. 15. When the braking-resistor wiring is unshielded, ensure a minimum spacing of 0.3m (12 in) from signal wiring. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-35 Issue code: udiu5 www.mroelectric.com Key to symbols Single power cable Optional external Three-core power cable or braking resistor three single power cables Ground cable Connection to cable armour or shield Maximum length: 50mm (2 in) Alternative safety ground connection Armoured or shielded cable (3-phase + ground) 5 − 10mm 13 ( /4 − /8 in) No sensitive circuits permitted in this zone L1 L2 L3 Control cables to the Drives Drive RFI filter Output 3 Output 2 Output 1 0V Ground Host controller _ L1 L2 L3 UVW + AC supply L1 ≤100mm Isolator (4 in) Contactor L2 Fuses or L3 MCB Back-plate Ground Power-ground bus-bar Enclosure Figure 2–22 Wiring guidelines for compliance with EMC emission standards (model sizes 1 and 2) Unidrive model sizes 1 to 4 Installation Guide 2-36 Installing the Drive Issue code: udiu5 www.mroelectric.com Compliance with EMC emission standards (model sizes 1 and 2) General features Special features for EMC 1. Single power ground bus-bar or low-impedance 12. Drive heatsink directly grounded to the ground terminal. back-plate using the metal mounting-brackets. Ensure that the screws make direct electrical 2. Incoming AC supply ground connected to the connection to the back-plate, for example by power ground bus-bar. using screw threads tapped in the backplate. 3. Connect grounds of any other circuits to the 13. RFI filter mounted at the side of the Drive. 1 3 power ground bus-bar. Ensure a separation of 5 to 10mm ( / to / in) 4 8 from the Drive. The RFI filter casing is directly 4. Site ground if required. grounded to the back-plate by the fixing screws. 5. Metal back-plate, safety bonded to power ground bus-bar. 14. A shielded (screened) or steel-wire armoured cable must be used to connect the Drive to the 6. System isolator, circuit contactors and motor. The shield must be bonded to the fuses/MCB. back-plate using an uninsulated metal cable- 7. Alternative position for Drive fuses. clamp. The clamp must be positioned no further than 100mm (4 in) from the Drive. 8. Optional braking resistor mounted externally, protected and shielded by a metal grille. 15. Connect the shield of the motor cable to the ground terminal of the motor frame using a link 9. Thermal overload device to protect the that is as short as possible and not exceeding braking resistor. 50mm (2 in) in length. A full 360° termination of the shield to the terminal housing of the 10. Alternative safety ground for the motor. motor is beneficial. 11. Motor-frame ground connection, if required. 16. Ensure the AC supply and ground cables are at least 100mm (4 in) from the Drive. 17. Avoid placing sensitive signal circuits in a zone extending 0.3m (12 in) all around the Drive. 18. Unshielded wiring to the optional braking resistor(s) may be used, provided the resistor is either in the same enclosure as the Drive or the wiring does not run external to the enclosure. When the braking-resistor wiring is unshielded, ensure a minimum spacing of 0.3m (12 in) from signal wiring and the AC supply wiring to the RFI filters. 19. If the control circuit 0V is to be grounded, this should be done at the host controller (eg. PLC) and not at the Drive. This is to avoid injecting noise currents into the 0V circuit. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-37 Issue code: udiu5 www.mroelectric.com Key to symbols Single power cable Optional external Three-core power cable or braking resistor three single power cables Ground cable Connection to cable armour or shield Maximum length: 50mm (2 in) Drive Alternative safety ground connection Armoured or shielded cable (3-phase + ground) _ L1 L3 V + No sensitive circuits permitted in this zone L2 U W Control cables to the Drives 150mm ≤150mm Output 3 (6 in) (6 in) Output 2 Output 1 L1´ L2´ L3´ E´ 0V LOAD Ground RFI filter Host LINE controller L1 L2 L3 E AC supply L1 Isolator Contactor L2 Fuses or L3 MCB Back-plate Ground Power-ground bus-bar Enclosure Figure 2–23 Wiring guidelines for compliance with EMC emission standards (model sizes 3 and 4) Unidrive model sizes 1 to 4 Installation Guide 2-38 Installing the Drive Issue code: udiu5 www.mroelectric.com Compliance with EMC emission standards (model sizes 3 and 4) 15. RFI filter mounted 150mm (6 in) from the Drive. General features The RFI filter casing is directly grounded to the 1. Single power ground bus-bar or low-impedance back-plate by the fixing screws. Minimize the ground terminal. length of cables between the Drive and RFI filter. 2. Incoming AC supply ground connected to the power ground bus-bar. 16. A shielded (screened) or steel-wire armoured cable must be used to connect the Drive to the 3. Connect grounds of any other circuits to the motor. The shield must be bonded to the power ground bus-bar. back-plate using an uninsulated metal cable- clamp. The clamp must be positioned no 4. Site ground if required. further than 150mm (6 in) from the Drive. 5. Metal back-plate, safety bonded to power 17. Connect the shield of the motor cable to the ground bus-bar. ground terminal of the motor frame using a link that is as short as possible and not exceeding 6. System isolator, circuit contactors and 50mm (2 in) in length. A full 360° termination fuses/MCB. of the shield to the terminal housing of the 7. Alternative position for Drive fuses. motor is beneficial. 8. Optional braking resistor mounted externally, 18. Ensure the AC supply and ground cables are at protected and shielded by a metal grille. least 100mm (4 in) from the motor cable. 9. Thermal overload device to protect the 19. Avoid placing sensitive signal circuits in a zone braking resistor. extending 0.3m (12 in) all around the Drive. 10. Alternative safety ground for the motor. 20. Unshielded wiring to the optional braking resistor(s) may be used, provided the resistor is 11. Motor-frame ground connection, if required. either in the same enclosure as the Drive or the wiring does not run external to the enclosure. Special features for EMC When the braking-resistor wiring is unshielded, ensure a minimum spacing of 0.3m (12 in) from 12. Size 4 models only The AC supply cable signal wiring and the AC supply wiring to the must be shielded (screened) or steel-wire RFI filters. armoured. Bond the shield or armour to the enclosure wall using standard cable and gland 21. If the control circuit 0V is to be grounded, this fixings. should be done at the host controller (eg. PLC) and not at the Drive. This is to avoid injecting 13. Size 4 models only Back-plate electrically noise currents into the 0V circuit. bonded to the enclosure wall using a short, low-inductance connections (eg. two flat, 1 1 braided cables of 12mm x 2.3mm ( / x / inch) 2 8 nominal size, or a single braided cable of equivalent dimensions). 14. Drive heatsink directly grounded to the back-plate using fixing screws. Screw threads tapped into the back-plate must be used to ensure that a direct electrical connection is made. An unpainted back-plate (eg. zinc- plated steel) is required. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-39 Issue code: udiu5 www.mroelectric.com 2.8 Variations in the EMC wiring recommendations From the Drive Control wiring Control wiring that connects to the following in the control module... • Terminals 3 to 11, and 22 to 31 • Encoder D-type connector • Option module connectors ... and exits the enclosure must have either of the Back-plate following additional treatments: • Pass the control cable(s) through a ferrite Enclosure ring (part number 3225-1004). More than To the motor one cable can pass through a ferrite ring. Ensure the length of cable between the ferrite ring and the Drive is not greater than 125mm (5 in). • Use one or more cables having a separate (Refer to Key to symbols in Figure 2–22) overall shield. Bond this shield(s) to the Figure 2–24 Connecting the motor cable to back-plate using an uninsulated metal clamp. a terminal block in the enclosure Position the clamp not further than 100mm (4 in) from the Drive. Do not make any other connections to either end of the Using a motor isolator-switch overall shield. The motor cable shields should be connected by a Interruptions to the motor cable very short conductor having a low inductance. The use of a flat metal coupling-bar is recommended; The motor cable should ideally be a single piece of conventional wire is not suitable. shielded or armoured cable having no interruptions. In some situations it may be necessary to interrupt The shields should be bonded directly to the the cable, as in the following examples: coupling-bar using uninsulated metal cable-clamps. Keep the length of the exposed power conductors Connecting the motor cable to a terminal block to a minimum and ensure that all sensitive in the Drive enclosure equipment and circuits are at least 0.3m (12 in) Fitting a motor isolator switch for safety when away. work is done on the motor The coupling-bar may be grounded to a known In these cases the following guidelines should be low-impedance ground nearby, for example a large followed. metallic structure which is connected closely to the Drive ground. Terminal block in the enclosure The motor cable shields should be bonded to the back-plate using uninsulated metal cable-clamps Isolator which should be positioned as close as possible to the terminal block. Keep the length of power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3m (12 in) away from the terminal block. From the To the Drive motor Coupling bar (If required) (Refer to Key to symbols in Figure 2–22) Figure 2–25 Connecting the motor cable to an isolator switch Unidrive model sizes 1 to 4 Installation Guide 2-40 Installing the Drive Issue code: udiu5 www.mroelectric.com 2.9 Signal connections The signal connections to be made depend on the method of control to be used. Refer to Chapter 2 Getting Started, Chapter 3 Setting up the Drive and Appendix C Signal Connections in the User Guide. Unidrive model sizes 1 to 4 Installation Guide Installing the Drive 2-41 Issue code: udiu5 www.mroelectric.com Unidrive model sizes 1 to 4 Installation Guide 2-42 Installing the Drive Issue code: udiu5 www.mroelectric.com Before connecting the AC supply to the Drive, it is Standard squirrel-cage induction motors are important that you understand the operating designed for single-speed operation. If it is controls and their operation. If in doubt, do not intended to use the capability of the Drive to run a adjust the Drive. Damage may occur, or lives put at motor at speeds above its designed maximum, it is risk. Carefully follow the instructions in this strongly recommended that the manufacturer is Installation Guide. consulted first. Before making adjustments to the Drive, ensure all Low speeds may cause the motor to over-heat personnel in the area are warned. Make notes of all because the cooling fan becomes less effective. adjustments that are made. The motor should then be fitted with a protection thermistor. If necessary, a separate cooling fan should be used. 1.7 Risk analysis If a Drive is to be used to control a number of motors, special measures need to be taken to ensure In any application where a malfunction of the Drive protection of the motors; refer to Motor protection could lead to damage, loss or injury, a risk analysis in Appendix A Motor Information. must be carried out, and where necessary, further measures taken to reduce the risk. This would normally be an appropriate form of independent 1.9 Adjusting parameters safety back-up system using simple electro- mechanical components. Some parameters have a profound effect on the operation of the Drive. They must not be altered without careful consideration of the impact on the 1.8 Motor controlled system. Measures must be taken to prevent unwanted changes due to error or Ensure the motor is installed in accordance with the tampering. manufacturer’s recommendations. Ensure the motor shaft is not exposed. Unidrive model sizes 1 to 4 Installation Guide 1-2 Safety Information Issue code: udiu5 www.mroelectric.com Unidrive and Unidrive VTC (at 50° °C ambient temperature) Model Maximum permissible continuous output current 3kHz 4.5kHz 6kHz 9kHz 12kHz UNI 1401 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A UNI 1402 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A UNI 1403 3.8 A 3.8 A 3.8 A 3.8 A 3.3 A UNI 1404 5.6 A 5.6 A 5.1 A 4.0 A 3.3 A UNI 1405 6.9 A 5.9 A 5.1 A 4.0 A 3.3 A UNI 2401 12.0 A 12.0 A 12.0 A 11.6 A 9.7 A UNI 2402 16.0 A 16.0 A 14.7 A 11.6 A 9.7 A UNI 2403 20.0 A 17.3 A 14.7 A 11.6 A 9.7 A UNI 3401 34.0 A 34.0 A 28.0 A 21.0 A 17.9 A UNI 3402 40.0 A 34.0 A 28.0 A 21.0 A 17.9 A UNI 3403 44.0 A 36.0 A 31.0 A 24.0 A 20.6 A UNI 3404 44.0 A 36.0 A 31.0 A 24.0 A 20.9 A UNI 3405 50.0 A 41.0 A 34.0 A 26.0 A 23.0 A UNI 4401 95 A 85 A 75 A 60 A UNI 4402 105 A 85 A 75 A 60 A UNI 4403 135 A 105 A 85 A 65 A UNI 4404 180 A 150 A 125 A 95 A UNI 4405 190 A 150 A 125 A 95 A Unidrive model sizes 1 to 4 Installation Guide C-2 Data Issue code: udiu5 www.mroelectric.com Unidrive LFT (at 9kHz PWM switching frequency) Model Nominal Maximum permissible output current Nominal AC rating * supply current Standard Continuous Continuous duty-cycle operation operation operation at 40°C at 50° °C at 40° °C UNI 1401LFT 0.75 kW 1.0 HP 2.1 A 2.1 A 2.1 A 3.1 A UNI 1402LFT 1.1 kW 1.5 HP 2.8 A 2.8 A 2.8 A 3.2 A UNI 1403LFT 1.5 kW 2.0 HP 3.8 A 3.8 A 3.3 A 5.5 A UNI 1404LFT 2.2 kW 3.0 HP 5.6 A 4.0 A 3.3 A 8.4 A UNI 1405LFT 4.0 kW 5.0 HP 9.5 A 4.3 A 3.3 A 9.5 A UNI 2401LFT 5.5 kW 7.5 HP 12.0 A 12.0 A 11.0 A 13.7 A UNI 2402LFT 7.5 kW 10 HP 16.0 A 14.2 A 11.0 A 16.3 A UNI 2403LFT 11.0 kW 15 HP 25.0 A 14.2 A 11.0 A 24.3 A UNI 3401LFT 15.0 kW 20 HP 34.0 A 28.0 A 21.0 A 34.0 A UNI 3402LFT 18.5 kW 25 HP 40.0 A 28.0 A 21.0 A 39.0 A UNI 3403LFT 22.0 kW 30 HP 46.0 A 32.0 A 24.0 A 46.0 A UNI 3404LFT 30.0 kW 40 HP 60.0 A 33.0 A 24.0 A 59.0 A UNI 3405LFT 37.0 kW 50 HP 70.0 A 35.0 A 26.0 A 74.0 A UNI 4401LFT 45 kW 60 HP 96 A 70 A 57 A 96 A UNI 4402LFT 55 kW 75 HP 124 A 70 A 57 A 120 A UNI 4403LFT 75 kW 100 HP 156 A 80 A 61 A 151 A UNI 4404LFT 90 kW 125 HP 180 A 100 A 77 A 173 A UNI 4405LFT 110 kW 125 HP 202 A 100 A 77 A 190 A * The nominal rating applies when the AC supply voltage is 400V. The absolute maximum rating is determined by the maximum continuous output current and maximum permissible AC supply voltage. Unidrive model sizes 1 to 4 Installation Guide Data C-3 Issue code: udiu5 www.mroelectric.com AC supply requirements Altitude Voltage: 380V to 480V ±10% Altitude range: 0 to 4000m (13000 ft), subject to the following conditions: No. of phases: 3 1000m to 4000m (3300 ft to 13000 ft) above sea level: de-rate the maximum output current Maximum supply imbalance: from the specified figure by 1% per 100m 2% negative phase sequence (equivalent to 3% (330 ft) voltage imbalance between phases) Frequency range: 48 to 62 Hz Vibration Line reactors Tested to ≤0.5g as specified in IEC 68–2–34 When one of the following model sizes... Ingress protection UNI 1401 UNI 1402 Gland plate(s) not fitted: IP00 UNI 1403 Gland plate(s) fitted; cable glands not fitted: IP10 UNI 1404 Gland plate(s) fitted; cable-glands fitted: ... is used on an AC supply of 175kVA or larger, it is IP40, NEMA 1 recommended that a line reactor of 2% reactance is included between the AC supply and the Drive. DC-bus Model sizes 1405 and larger have an internal Overall dimensions choke. H Height including surface mounting A line reactor reduces the risk of damage to the brackets Drive resulting from severe disturbances on the W Width supply network. D Projection forward of panel when surface mounted Motor requirements F Projection forward of panel when through-panel mounted Number of phases: 3 R Projection rear of panel when through-panel mounted Voltage: 380V ~ 480V ±10% Dimension Model size Temperature, humidity 1 2 34 and cooling method 366mm 366mm 368mm 765mm H 3 3 1 1 14 / 14 / 14 / in 30 / 8 8 4 8 Ambient temperature range: W 95mm 190mm 375mm 500mm 0°C to 50°C (32°F to 122°F). Output current 3 1 3 11 3 / in 7 / in 14 / in 19 / in 4 2 4 16 de-rating must be applied at ambient temperatures D 200mm 200 mm 260mm 260mm between 40°C and 50°C (122°F) (absolute 7 7 1 1 7 / in 7 / in 10 / 10 / maximum). 8 8 4 4 F 120mm 120mm 120mm 120mm 1 1 1 1 Minimum temperature at power-up: –10°C (14°F) 4 / in 4 / in 4 / in 4 / in 4 4 4 4 80mm 80mm 140mm 140mm R Cooling method: Forced convection 1 1 1 1 3 / in 3 / in 5 / in 5 / in 8 8 2 2 Maximum humidity: 95% non-condensing at 40°C (104°F) Weights Storage temperature range: Model size kg lb –40°C to 50°C (–40°F to 122°F) 1 4 8.8 Maximum storage time: After each 12 months, the 2 817 capacitors will need re-forming; refer to the supplier of the Drive. 3 22 49 70 154 4 Unidrive model sizes 1 to 4 Installation Guide C-4 Data Issue code: udiu5 www.mroelectric.com Conducted emission from the Drive meets the Electromagnetic compatibility (EMC) requirements of EN50081–2 (generic emission standard for the industrial environment) over a wide This is a summary of the EMC performance of the range of conditions. In addition, Drive model sizes 1 Drive. For full details, refer to the Unidrive EMC Data to 3 meet the radiated emission requirements of this Sheet which can be obtained from a Drive Centre or standard. The emission limits in EN50081–2 are distributor listed at the end of the User Guide. similar to CISPR11 and EN55011 Class A. Under restricted conditions, the conducted emission Immunity meets EN50081–1 (generic emission standard for the Compliance with immunity standards does not residential, commercial and light industrial depend on installation details. Drives meet environment). This is similar to CISPR11 and EN55011 EN50082–2 (generic immunity standard for the Class B. industrial environment) and the following The optional RFI filter specified below must be used: specifications from the IEC1000–4 group (derived from IEC801): Drive model Use RFI filter... Part 2, Electrostatic discharge: Level 3 Type Part number A Part 3, Radio frequency field: Level 3 UNI 1401 4200–0010 UNI 1402 A 4200–0010 Part 4 Transient burst: UNI 1403 A 4200–0010 Level 4 at the control terminals A Level 3 at the power terminals UNI 1404 4200–0010 UNI 1405 A 4200–0010 Part 5, Surge (at the AC supply terminals) (as specified by EN50082–2 informative annex): UNI 2401 B 4200–0027 Level 4 line-to-ground UNI 2402 B 4200–0027 Level 3 line-to-line UNI 2403 B 4200–0027 Part 6, Conducted radio frequency: Level 3 C UNI 3401 4200–1051 UNI 3402 C 4200–1051 Emission UNI 3403 C 4200–1051 Compliance with emission standards depends on UNI 3404 D 4200–1071 rigorous adherence to the installation guidelines, UNI 3405 D 4200–1071 including the use of the specified RFI filter in the AC UNI 4401 E 4200–1111 supply circuit. Compliance also depends on the PWM switching frequency used in the output stage UNI 4402 F 4200–1171 of the Drive, and the length of the motor cable. For UNI 4403 F 4200–1171 full details, refer to the Unidrive EMC Data Sheet which UNI 4404 F 4200–1171 can be obtained from a Drive Centre or distributor listed at the end of the User Guide. H UNI 4405 4200–1220 Unidrive model sizes 1 to 4 Installation Guide Data C-5 Issue code: udiu5 www.mroelectric.com Note Power Drive Systems standard EN61800–3 If a Power Drive System is included as part of equipment covered by a separate EMC The Drive meets the immunity requirements of product standard, the EMC standard for the EN61800–3 irrespective of the environment in which complete equipment applies. it is operating. The emission requirements of this standard are also Frequencies and speed met depending on the environment category, as shown in the table at the bottom of the page: PWM switching frequency EN61800–3 defines the following: Unidrive and Unidrive VTC: 3kHz nominal (selectable up to 12kHz) • The first environment as one that Unidrive LFT: 9kHz nominal (selectable from includes domestic premises. It also includes 3kHz to 12kHz) establishments directly connected without intermediate transformers to a low-voltage Maximum output frequency (open-loop): 2000Hz power supply network which supplies Maximum speed (closed-loop): 30 000 RPM buildings used for domestic purposes. Speed regulation: • The second environment is one that (open-loop): 1 ~ 2% includes all establishments other than those (closed-loop): 0.01% directly connected to a low-voltage power supply network which supplies buildings Speed control range: used for domestic purposes. (open-loop): >50:1 • Restricted distribution is defined as a (closed-loop): >1000:1 mode of sales distribution in which the manufacturer restricts the supply of Starts per hour equipment to suppliers, customers or users who separately or jointly have technical By electronic control: unlimited competence in the EMC requirements of the application of Drives. By interrupting the AC supply: model sizes 1 and 2: ≤20 model sizes 3 and 4: ≤10 Power Drive Systems standard EN61800–3 Model size Environment category First environment Second environment UNI 1401 ~ UNI 1405 Restricted distribution only: specified RFI filter No RFI filter required * required (Rated input current of Drive <25A) UNI 2401, UNI 2402 Restricted distribution only: specified RFI filter No RFI filter required * required (Rated input current of Drive <25A) UNI 2403 Specified RFI filter required No RFI filter required * (Rated input current of Drive >25A) UNI 3401 ~ UNI 3405 Specified RFI filter required No RFI filter required * (Rated input current of Drive >25A) UNI 4401 ~ UNI 4405 Using the specified RFI filters and following the No RFI filter required * wiring guidelines given in Figure 2–23 may not ensure that the radiated emission limits are met. Additional filtering may be required in this environment. * RFI filter(s) recommended where sensitive electronic systems are operating nearby. Unidrive model sizes 1 to 4 Installation Guide C-6 Data Issue code: udiu5 www.mroelectric.com Closed-loop speed resolution Accuracy and resolution Unidrive and Unidrive LFT only... The following data applies to the Drive only; it does Preset speed reference: 1 RPM not include the performance of the source of the Precision speed reference: 0.01 RPM control signals. Analog input 1: 0 RPM * Open-loop frequency resolution... * The speed-loop algorithm ensures that the steady-state speed can change by infinitely Preset frequency reference: 0.1Hz small amounts in response to changes in the Precision frequency reference: 0.001Hz reference from these inputs. Open-loop frequency accuracy... Closed-loop speed accuracy Unidrive and Unidrive LFT only... Preset frequency reference: 0.03Hz or 0.01% of the reference, whichever is the larger value Preset or precision speed reference: Precision frequency reference: 0.0001Hz or RPM or 0.01% of the reference, 0.00016 0.01% of the reference, whichever is the larger whichever is the larger value value Dissipation (all version) Model Nominal Maximum total power dissipation rating 3kHz 4.5kHz 6kHz 9kHz 12kHz UNI 1401 0.75kW 1.0HP 80 W 80 W 90 W 90 W 90 W UNI 1402 1.1kW 1.5HP 90 W 90 W 100 W 100 W 110 W UNI 1403 1.5kW 2.0HP 100 W 110 W 110 W 120 W 130 W UNI 1404 2.2kW 3.0HP 130 W 130 W 140 W 150 W 150 W UNI 1405 4.0kW 5.0HP 180 W 190 W 190 W 190 W 170 W UNI 2401 5.5kW 7.5HP 210 W 230 W 250 W 280 W 310 W UNI 2402 7.5kW 10HP 270 W 290 W 310 W 320 W 310 W UNI 2403 11.0kW 15HP 400 W 380 W 360 W 330 W 310 W UNI 3401 15.0kW 20HP 570 W 620 W 670 W 660 W 630 W UNI 3402 18.5kW 25HP 660 W 720 W 730 W 660 W 630 W UNI 3403 22.0kW 30HP 730 W 800 W 770 W 730 W 700 W UNI 3404 30.0kW 40HP 950 W 830 W 790 W 740 W 710 W UNI 3405 37.0kW 50HP 1090 W 990 W 920 W 850 W 800 W UNI 4401 45kW 60HP 1460 W 1610 W 1630 W 1530 W UNI 4402 55kW 75HP 1910 W 1780 W 1670 W 1560 W UNI 4403 75kW 100HP 2370 W 2130 W 2030 W 1860 W UNI 4404 90kW 125HP 2640 W 2890 W 2700 W 2470 W UNI 4405 110kW 125HP 2970 W 2910 W 2720 W 2490 W The default PWM switching frequency is as follows... Unidrive and Unidrive VTC: 3kHz Unidrive LFT: 9kHz Unidrive model sizes 1 to 4 Installation Guide Data C-7 Issue code: udiu5 www.mroelectric.com Power dissipation C.2 Optional RFI filters Type Part number Power Ratings dissipation at rated current Type Part number Max. Ingress A 4200–0010 25 W continuous protection current B 4200–0027 40 W A 4200–0010 10 A IP20 C 4200–1051 60 W B 4200–0027 27 A IP20 D 4200–1071 100 W C 4200–1051 50 A IP 00 E 4200–1111 120 W D 4200–1071 75 A IP 00 F 4200–1171 150 W E 4200–1111 110 A IP 00 H 4200–1220 200 W F 4200–1171 170 A * IP 00 H 4200–1220 300 A IP 00 Ground leakage current * Above 40°C (104°F), the current rating is reduced Ground-leakage current when the AC supply is 400V by 1.6A/°C (0.88A/°F) up to 50°C. at 50Hz is as follows: Maximum current overload: Condition A B C to H 150% of rated current for 1 minute in a 10 minute Balanced supply phase-to- 5.6mA 7.4mA 55mA period. phase and phases to ground Voltage (phase-to-phase and phase-to-ground): One phase disconnected 41mA 57.9mA 350mA 480V +10% For other AC supply voltages and frequencies, scale AC supply frequency: 48 to 62 Hz the values of leakage current proportionally. Discharge resistors Temperature A and B: 330KΩ in a star network between phases, Type Part number Maximum Case ambient temperature with the star point connected by a 1MΩ resistor to temperature rise at rated ground. at rated current current C to H: 10MΩ between each phase and ground. A 4200–0010 50 °C (122°F) <30°C (86°F) The discharge resistors are fitted internally. B 4200–0027 50 °C (122°F) <40°C (104°F) C 4200–1051 50 °C (122°F) <40°C (104°F) D 4200–1071 50 °C (122°F) <40°C (104°F) E 4200–1111 50 °C (122°F) <40°C (104°F) F 4200–1171 40 °C (104°F) * <55°C (131°F) H 4200–1220 40 °C (104°F) * <40°C (104°F) * Above 40°C (104°F), the current rating is reduced by 1.6A/°C (0.88A/°F) up to 50°C (122°F). Unidrive model sizes 1 to 4 Installation Guide C-8 Data Issue code: udiu5 www.mroelectric.com Overall dimensions Type Part Dimension number HW D A 4200–0010 396mm 50mm 114.5mm 9 15 1 15 / in 1 / in 4 / in 16 16 2 B 4200–0027 406mm 75mm 114.5mm 15 1 16 in 2 / in 4 / in 16 2 C 4200–1051 330mm 190mm 145mm 1 11 13 in 7 / in 5 / in 2 16 D 4200–1071 330mm 190mm 145mm 1 11 13 in 7 / in 5 / in 2 16 E 4200–1111 440mm 200mm 145mm 5 7 11 17 / in 7 / in 5 / in 16 8 16 F 4200–1171 490mm 200mm 145mm 1 7 11 19 / in 7 / in 5 / in 4 8 16 H 4200–1220 590mm 200mm 145mm 1 7 11 23 / in 7 / in 5 / in 4 8 16 Weights Type Part kg lb number A 4200–0010 2 5 B 4200–0027 2.7 6 C 4200–1051 7.4 16 D 4200–1071 8 18 E 4200–1111 12.3 27 F 4200–1171 16 35 H 4200–1220 26 57 Unidrive model sizes 1 to 4 Installation Guide Data C-9 Issue code: udiu5 www.mroelectric.com Unidrive model sizes 1 to 4 Installation Guide C-10 Data Issue code: udiu5 www.mroelectric.com Unidrive model sizes 1 to 4 Installation Guide B-2 UL listing Issue code: udiu5 www.mroelectric.com Unidrive model sizes 1 to 4 Installation Guide A-2 Motor connections Issue code: udiu5 www.mroelectric.com Declaration of Conformity These products comply with the Low Voltage Control Techniques plc Directive 73/23/EEC, the Electromagnetic The Gro Compatibility (EMC) Directive 89/336/EEC and the Newtown CE Marking Directive 93/68/EEC. Powys UK SY16 3BE UNI 1401 UNI 1402 UNI 1403 UNI 1404 UNI 1405 UNI 2401 UNI 2402 UNI 2403 W. Drury UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 Technical Director UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 Newtown The AC variable speed drive products listed above, Date: 5th February 1998 including the VTC and LFT variants, have been designed and manufactured in accordance with the following European harmonised, national and international standards: These electronic Drive products are EN60249 Base materials for printed circuits intended to be used with appropriate motors, controllers, electrical IEC326-1 Printed boards: general information for the specification writer protection components and other equipment to form complete end IEC326-5 Printed boards: specification for single- and double-sided printed boards with products or systems. Compliance with plated-through holes safety and EMC regulations depends IEC326-6 Printed boards: specification for multilayer upon installing and configuring Drives printed boards correctly, including using the specified IEC664-1 Insulation co-ordination for equipment input filters. The Drives must be within low-voltage systems: principles, installed only by professional requirements and tests assemblers who are familiar with EN60529 Degrees of protection provided by requirements for safety and EMC. The enclosures (IP code) assembler is responsible for ensuring UL94 Flammability rating of plastic materials that the end product or system complies with all the relevant laws in UL508C Standard for power conversion equipment the country where it is to be used. EN50081-1 Generic emission standard for the Refer to the Installation Guide. A residential, commercial and light industrial environment Unidrive EMC Data Sheet is also available giving detailed EMC information. EN50081-2 Generic emission standard for the industrial environment EN50082-2 Generic immunity standard for the industrial environment EN61800-3 Adjustable speed electrical power drive systems – Part 3: EMC product standard including specific test methods Unidrive model sizes 1 to 4 Installation Guide ii Issue code: udiu5 www.mroelectric.com General information The manufacturer accepts no liability for any consequences resulting from inappropriate , negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive (Drive) with the motor. The contents of this User Guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the User Guide, without notice. All rights reserved. No parts of this User Guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by any information- storage or retrieval system, without permission in writing from the publisher. Copyright © September 1998 Control Techniques Drives Ltd Author: RFD Issue Code: udiu5 Issue Date: September 1998 S/W Version: 03.XX.XX www.mroelectric.com