Altivar 58 Split-Box Kit Combination Bypass Package for Adjustable Speed Drive Controllers

Transcription

1 Altivar 58 Split-Box Kit Combination Bypass Package for Adjustable Speed Drive Controllers Class to 25 hp, 460 V and 1 to10 hp, 208/230 V Instruction Bulletin Retain for future use.

2 Altivar 58 Split-Box Kit Hazard Categories and Special Symbols 09/2004 HAZARD CATEGORIES AND SPECIAL SYMBOLS Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of either symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. CAUTION CAUTION, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in property damage. PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. PRODUCT SUPPORT For support and assistance, contact the Product Support Group. The Product Support Group is staffed from 8:00 am until 6:00 pm Eastern time to assist with product selection, start-up, and diagnosis of product or application problems. Emergency phone support is available 24 hours a day, 365 days a year. Telephone Toll Free 888-Square D ( ) drive.products.support@us.schneider-electric.com Fax Schneider Electric All Rights Reserved

3 Altivar 58 Split-Box Kit 09/2004 Table of Contents SECTION 1: SECTION 2: INTRODUCTION AND TECHNICAL CHARACTERISTICS RECEIVING, HANDLING, AND STORAGE Related Documentation... 5 Terminology... 5 Part Number Configuration... 6 Nameplate Identification... 6 Technical Characteristics... 7 Input Current Ratings... 8 Specifications... 8 Short Circuit Ratings... 8 Receiving and Preliminary Inspection... 9 Storing the Equipment... 9 Unpacking the ATV58 Split-Box Kit and Power Converter Before Installing the Split-Box Kit Before Wiring the Power Converter Handling the Controller SECTION 3: INSTALLATION Precautions Shipping weights Watts Loss/Heat Dissipation Data Dimensions and Weights for Wall or Panel Mounting Wire Routing and Interconnection Wire Class Noise Class Voltage Class Wiring Methods Terminal Strip Locations Power Wiring Control Wiring SECTION 4: OPERATION Sequence of Operation and Configuration Terminal Command Mode Versus Keypad Command Mode Programming the Power Converter Power Circuit Y Full Voltage Bypass Operator Controls General Arrangement and Operation Adjustable Speed Operation Bypass Operation Freeze/Firestat Interlocks (if used) Pilot Light Cluster Power Isolation (CAM) Switch Line Reactor Smoke Purge Function (Selectable) Automatic Transfer to Bypass Function (Selectable) Auxiliary Drive Run Contact Auxiliary Bypass Run Contact Auxiliary Fault Contact Proper Drive Isolation Method Power and Control Circuit Elementary Diagram SECTION 5: MAINTENANCE Technical Support Class 8839 Altivar 58 Split-Box Kit Troubleshooting Sheet SECTION 6: RECOMMENDED SPARE PARTS Recommended Spare Parts Schneider Electric All Rights Reserved 3

4 Altivar 58 Split-Box Kit Table of Contents 09/ Schneider Electric All Rights Reserved

5 Altivar 58 Split-Box Kit 09/2004 Section 1 Introduction and Technical Characteristics SECTION 1 INTRODUCTION AND TECHNICAL CHARACTERISTICS This bulletin provides installation and maintenance information for the Altivar 58 (ATV58) Split-Box Kit. The Class 8839 ATV58 Split-Box Kit is a combination device composed of a power circuit box with options, and a wall-mountable back pan for use with a power converter. The Split-Box Kit is configured with a full voltage bypass power circuit configuration for customer installation and commissioning. NOTE: The ATV58 Split-Box Kit must only be used with the ATV58 power converters specified on the nameplate. RELATED DOCUMENTATION Terminology In addition to this bulletin, refer to the following documentation which may have been purchased for the ATV58 Split-Box Kit: Instruction Bulletin VVDED397048US, Altivar 58 Type H AC Drive Installation Guide, describes the installation, operation, and characteristics of the ATV58 Drive Controller when used as a component of the ATV58 Split-Box Kit. Instruction Bulletin VVDED397047US, Altivar 58 Adjustable Speed Drive Controllers Keypad Display VW3A Instruction Bulletin , Safe Handling, Installation, Operation, and Maintenance of Electrical Equipment. NOTE: To replace missing documents, contact your local Schneider Electric field office. This instruction bulletin uses the following terminology. The terminology distinctions minimize confusion when discussing installation and adjustment practices. ATV58 Split-Box Kit refers to the power circuit box mounted below the power converter. Power converter refers to the ATV58HU18 through ATV58HD23 controllers, described in instruction bulletin number VVDED397048US, when used as a component of the ATV58 Split-Box Kit. The power converter and its accessories (such as the Keypad Display and option cards) are purchased and installed separately from the Split-Box Kit. Drive controller or controller refers to the combination of the power converter, enclosure, and the power and control circuits that constitute the ATV58 Split-Box product. Drive refers to the combination of the controller and motor Schneider Electric All Rights Reserved 5

6 Altivar 58 Split-Box Kit Section 1 Introduction and Technical Characteristics PART NUMBER CONFIGURATION /2004 The part number, located on the nameplate attached to the Split-Box Kit, is coded to describe the configuration and options present. Use Table 1 to translate the part number into a description of the drive controller. Table 1: Part Number Configuration Field Digit Characteristic Description Controller Style 58S = Altivar 58 TRX Drive (supplied by customer) C = 1 hp D = 2 hp E = 3 hp F = 5 hp G = 7.5 hp H = 10 hp J = 15 hp K = 20 hp L = 25 hp Horsepower Enclosure Type G = Type 1 General Purpose Voltage 2 = 200/208 Vac 3 = 230/240 Vac 4 = 460/480 Vac Power Circuit Y = Combination Full Voltage Bypass Each configuration includes: Standard Features, Control and Pilot Devices NAMEPLATE IDENTIFICATION Figure 1: Circuit breaker disconnect Power isolation (CAM) switch 3% minimum rated line reactor A06: HAND-COMM-AUTO selector switch and manual speed potentiometer AFC-OFF-BYPASS selector switch A07: Pilot light cluster: power on (red), drive run (green), bypass run (green), drive fault (yellow) Freeze/Firestat interlock Smoke purge (selectable) Auto transfer to Bypass (selectable) Auxiliary contacts for drive run, bypass run, and fault The nameplate for the ATV58 Split-Box Kit is located on the inside right side wall of the Split-Box Kit. This nameplate, shown in Figure 1, carries the controller class, type, and mod (options) listing. When identifying or describing ATV58 Split-Box Kits, use the data from this nameplate. ATV58 Split-Box Nameplate Part Number (ATV58 Split-Box) Permissible Input Voltage Basic ATV58 Converter Model Numbers Input Current and Coordinated Short Circuit Rating Horsepower/Kilowatt Rating OCPD Device Identification Line Terminations (wire size and terminal torques) Enclosure Environmental Rating Load Terminations (wire size and terminal torques) Factory Order Number (Q2C) and Item Number Plant Code (Seneca, SC) Schneider Electric All Rights Reserved

7 Altivar 58 Split-Box Kit 09/2004 Section 1 Introduction and Technical Characteristics TECHNICAL CHARACTERISTICS The power given in the tables below is for a switching frequency between 0.5 and 8 khz (VT). For switching frequency above 8 khz, if the duty cycle exceeds 60% (36 s maximum for a 60 s cycle), select the next higher horsepower-size drive controller. Table 2: Variable Torque Ratings 460 Vac ±10% Drive Controller Catalog Number Motor Power V 60 Hz (hp) Input Current (A) Output Current (A) Max. Transient Output Current 60 s (A) Standard Power Converter Part Number CE Filter 2 Power Converter Part Number 58SCG4YAA ATV58HU18N4ZU ATV58HU18N4ZU 58SDG4YAA ATV58HU29N4ZU ATV58HU29N4ZU 58SEG4YAA ATV58HU41N4ZU ATV58HU41N4ZU 58SFG4YAA ATV58HU54N4XZU ATV58HU72N4ZU 58SGG4YAA ATV58HU72N4XZU ATV58HU90N4ZU 58SHG4YAA ATV58HU90N4XZU 58SJG4YAA ATV58HD12N4XZU ATV58HD16N4ZU 58SKG4YAA ATV58HD16N4XZU ATV58HD23N4ZU 58SLG4YAA ATV58HD23N4XZU 1 Power shown is for a switching frequency between 0.5 and 8 khz and at steady state for ATV58HU18N4ZU through ATV58HD23N4XZU. 2 The CE filter version includes EMI/RFI filters for meeting the EMC Directives (EN55011 Class A) and the FCC limits for conducted motor noise emissions. Additional construction requirements include the use of shielded cable for both motor and control signal connections. Table 3: Variable Torque Ratings 230 VAC ±10% Drive Controller Catalog Number Motor Power V 60 Hz (hp) Input Current (A) Output Current (A) Max. Transient Output Current 60 s (A) CE Filter 2 Power Converter Part Number 58SCG3YAA ATV58HU29M2ZU 58SDG3YAA ATV58HU29M2ZU 58SEG3YAA ATV58HU41M2ZU 58SFG3YAA ATV58HU72M2ZU 58SGG3YAA ATV58HU90M2ZU 58SHG3YAA ATV58HD12M2ZU 1 Power shown is for a switching frequency between 0.5 and 8 khz and at steady state for ATV58HU29M2ZU through ATV58HD12M2ZU. 2 The CE filter version includes EMI/RFI filters for meeting the EMC Directives (EN55011 Class A) and the FCC limits for conducted motor noise emissions. Additional construction requirements include the use of shielded cable for both motor and control signal connections. Table 4: Variable Torque Ratings 208 Vac ±10% Drive Controller Catalog Number Motor Power V 60 Hz (hp) Input Current (A) Output Current (A) Max. Transient Output Current 60 s (A) CE Filter 2 Power Converter Part Number 58SCG2YAA ATV58HU29M2ZU 58SDG2YAA ATV58HU29M2ZU 58SEG2YAA ATV58HU41M2ZU 58SFG2YAA ATV58HU72M2ZU 58SGG2YAA ATV58HU90M2ZU 58SHG2YAA ATV58HD12M2ZU 1 Power shown is for a switching frequency between 0.5 and 8 khz and at steady state for ATV58HU29M2ZU through ATV58HD12M2ZU. 2 The CE filter version includes EMI/RFI filters for meeting the EMC Directives (EN55011 Class A) and the FCC limits for conducted motor noise emissions. Additional construction requirements include the use of shielded cable for both motor and control signal connections Schneider Electric All Rights Reserved 7

8 Altivar 58 Split-Box Kit Section 1 Introduction and Technical Characteristics 09/2004 Input Current Ratings All branch circuit components and equipment such as transformers, feeder cables, disconnect devices, and protective devices must be rated for the input current of the drive controller or the motor full load current, whichever is greater. The input current is stamped on the nameplate (see Figure 1 for the nameplate location). Branch circuit feeder protection must be sized according to NEC Article 430. Specifications Table 5: Specifications Input voltage 460 V ±10%; 208 V ±10%; or 230 V ±10% Displacement power factor Approximately 0.96 Input frequency 60 Hz ± 5% Output voltage Three-phase output, maximum voltage equal to input voltage Galvanic isolation Galvanic isolation between power and control (inputs, outputs, and power supplies) Frequency range of power converter 0.1 to 500 Hz (factory setting of 60 Hz maximum) Current limit 110% of nominal drive full load amperage (FLA) for 60 s Switching frequency Selectable from 0.5 to 16 khz [1] Speed reference Frequency resolution in analog reference Speed regulation AI1: 0 to +10 V, Impedance = 30 kω AI2: 4 to 20 ma, Impedance = 100 Ω 0 to 20 ma (reassignable, X Y range with keypad display) Through-cover speed potentiometer to AI1 0.1 for 100 Hz (10 bits) V/f: determined by motor slip, typically 3% SLFV (sensorless flux vector): 1% Efficiency Typically greater than 95% Reference sample time 5 ms Acceleration and deceleration ramps 0.1 to seconds (adjustable in 0.1 s increments) Motor protection Keypad display Storage temperature Operating temperature Humidity Class 10 overload protection with bypass option in addition to controller internal electronic thermal protection. Self-diagnostics with fault messages in three languages Also refer to instruction bulletin VVDED397047US 13 to +149 F ( 25 to +65 C) +14 to +104 F ( 10 to 40 C) 95% with no condensation or dripping water, conforming to IEC Altitude 3,300 ft (1000 m) maximum without derating; derating of the current by 1% for each additional 330 ft (100 m) Enclosure Type 1 Pollution degree Pollution degree 2 per NEMA ICS-1 and IEC Resistance to vibrations (Power converter only) Resistance to shocks (Power converter only) Transit test to shock Codes and standards [1] According to IEC : 1.5 mm zero to peak from 3 to 13 Hz 1 gn from 13 to 200 Hz According to IEC : 15 g, 11 ms Conforming to National Safe Transit Association and International Safe Transit Association test for packages weighing 100 lbs or less UL Listed per UL508A as incorporating Class 10 electronic and electromechanical overload protection. Conforms to applicable NEMA ICS, NFPA, IEC and ISO 9001 standards. Above 8 khz, if the duty cycle exceeds 60% (36 s maximum for a 60 s cycle), select the next higher horsepower-size drive controller for continuous operation. Short Circuit Ratings All ATV58 Split-Box Kit devices include a thermal magnetic circuit breaker as the overcurrent protective device (OCPD). All configurations are rated to 100,000 A short circuit current rating (symmetrical) Schneider Electric All Rights Reserved

9 Altivar 58 Split-Box Kit 09/2004 Section 2 Receiving, Handling, and Storage SECTION 2 RECEIVING, HANDLING, AND STORAGE CAUTION DAMAGED EQUIPMENT Do not operate any ATV58 Split-Box controller that appears damaged. Failure to follow this instruction can result in injury, or equipment damage. RECEIVING AND PRELIMINARY INSPECTION Storing the Equipment The ATV58 Split-Box Kit and power converter must be thoroughly inspected before it is stored or installed. Upon receipt: 1. Remove the Split-Box Kit and power converter from its packaging and visually inspect the exterior for shipping damage. 2. Ensure that the catalog number of the Split-Box Kit and power converter, which appears on the nameplate, agrees with the packaging slip and corresponding purchase order. 3. If you find any shipping damage, notify the carrier and your sales representative. CAUTION STACKING DURING STORAGE OR SHIPPING Do not stack ATV58 Split-Box Kits on top of each other. Do not place any material on top of the ATV58 Split-Box Kit. Store or ship the equipment in the original packaging. Failure to follow this instruction can result in equipment damage. If you plan to store the ATV58 Split-Box Kit and power converter after receipt, replace it in its original packaging and observe the storage temperature and humidity specifications in Table 5 on page 8. Storing the equipment in its original packaging until it reaches its final installation site protects the equipment and prevents damage to its exterior Schneider Electric All Rights Reserved 9

10 Altivar 58 Split-Box Kit Section 2 Receiving, Handling, and Storage 09/2004 Unpacking the ATV58 Split-Box Kit and Power Converter WARNING LIFTING HEAVY EQUIPMENT Lifting the equipment out of the carton requires two people. Use safe lifting procedures. Failure to follow these instruction can result in serious injury, or equipment damage. Handle the Split-Box Kit and power converter carefully to avoid damage to the internal components, frame, and exterior. Lift the Split-Box Kit out of its shipping carton, lifting with two people or a suitable lifting apparatus, and place it on a flat surface. Before Installing the Split-Box Kit Before installing the ATV58 Split-Box Kit: 1. If the kit is to be used before installing the power converter, loosen the thumbscrews on the Split-Box Kit cover, then remove the cover. Verify that each of the 7 converter power wires has wire nuts on the end of the wires, and that the CAM switch is set to 0 (OFF). Leave the top cover in place over the converter mounting opening at the top of the Split-Box Kit. Visually verify that all internal mounting hardware and terminal connection hardware is properly seated, securely fastened, and undamaged. Verify that all terminal screws are tight, all relays are properly seated, and all control transformer fuses are in place in the fuse block. 2. If the kit is to be used with the power converter installed, before installing the power converter verify that its catalog number matches the catalog number specified on the Split-Box Kit nameplate. The Split-Box kit must only be used with the ATV58 power converters specified on the nameplate. Also, visually verify that the control board on the power converter is properly seated, securely fastened, and undamaged. To install the power converter: Loosen the thumbscrews on the Split-Box cover, and then remove the cover. Remove the top cover over the opening for mounting the power converter at the top of the Split-Box Kit, and store it for future use in case the power converter is ever removed. Set the CAM switch to 0 (OFF). Visually verify that all internal mounting hardware and terminal connection hardware is properly seated and that the control transformer fuses are in place in the fuse block. Mount the power converter to the Split-Box Kit back panel by slipping the power converter up to the extension collar, and aligning the mounting feet of the power converter over the holes in the panel. Attach the power converter to the panel with the four taptite screws provided in the documentation bag. Install the communications card, if used, to the power converter Schneider Electric All Rights Reserved

11 Altivar 58 Split-Box Kit 09/2004 Section 2 Receiving, Handling, and Storage Before Wiring the Power Converter After the power converter is mounted to the Split-Box Kit: 1. Temporarily remove the power converter control terminal plug (TB2) with the control harness and power converter connectors attached. 2. Cut the six power wires (1, 2, 3, U, V, W) and ground wire (G) to the required length and strip the insulation back 0.5 in. Keep the wire nuts with the top cover plate for future use in case the power converter is ever removed for service or repair. 3. Connect the six power wires and the ground wire to the power converter terminal strip, and torque to the value shown in Table Reinsert the power converter control terminal plug, TB-2, into its receptacle, and insert the two converter control connectors, in place of the two supplied, into the power converter. 5. Set the CAM switch to 1 (ON). Table 6: Power Terminal Torque Values Power Converter ATV58H Torque lb-in (N m) U18N4, U29N4, U41N4 7.5 (0.85) U54N4, U72N4. U90N4 7.5 (0.85) D12N4. D16N4, D23N4 20 (2.26) U29M2, U41M2 7.5 (0.85) U72M2 7.5 (0.85) U90M2, D12M2 20 (2.26) Figure 2: Power Converter Terminals R1A R1B R1C R2A R2C AO1 COM AI1 +10 AI2 LI1 LI2 LI3 LI4 +24 S GND L1 L2 L3 PA PB U V W GND Power Connections Bottom View Power Converter S +24 LI4 LI3 LI2 LI1 AI2 +10 AI1 COM R2C R2A R1C R1B R1A TB Schneider Electric All Rights Reserved 11

12 Altivar 58 Split-Box Kit Section 2 Receiving, Handling, and Storage 09/2004 Handling the Controller When handling, moving, or lifting the controller, do not allow it to tip or drop. After removing the product from the packaging, the controller will require some type of mechanical lifting. This is true whether the power converter is installed or not. Handle the controller: With a hoist, attach a spreader bar to the two lifting holes on the Split- Box Kit panel (on either side of the power converter). See Figure 3. In a horizontal position, with the back of the controller resting on a flat surface. WARNING HANDLING AND LIFTING HAZARD Keep the area below any equipment being lifted clear of all personnel and property. Before lifting the panel: Inspect the lifting plates, holes, slots, or eyebolts for any damage Attach a spreader bar Keep the lifting force vertical Limit the sling angle to less than 45 Failure to observe these precautions can result in equipment damage, severe personal injury, or death. Figure 3: Max. 45 Hoisting the ATV58 Split-Box Kit Max. 45 Spreader Bar Lifting Force Enclosure with Lifting Plates Spreader Bar Lifting Force Enclosure with Eyebolts To hoist the controller, attach a spreader bar to the lifting slots located on top of the back panel. Refer to Figure 3. Handle the controller carefully to avoid damage to the internal components, frame, and exterior. Place the controller in an upright position. WARNING LIFTING HEAVY EQUIPMENT Keep the area below any equipment being lifted clear of all personnel and property. Use the lifting method shown in Figure 3. Failure to follow these instructions can result in death, serious injury, or equipment damage Schneider Electric All Rights Reserved

13 Altivar 58 Split-Box Kit 09/2004 Section 3 Installation SECTION 3 INSTALLATION PRECAUTIONS DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION AND ARC FLASH Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. This equipment must only be installed and serviced by qualified electrical personnel. Turn off all power supplying this equipment before working on or inside equipment. Always use a properly-rated voltage sensing device to confirm that power is off. Before servicing, remove all power then wait three minutes. Verify that no voltage is present. Replace all devices, doors, and covers before turning on power to this equipment. Failure to follow these instruction will result in death or serious injury. Follow these precautions when installing the ATV58 Split-Box Kit and power converter: The controller is suitable for installation in a pollution degree 2 environment, as defined in NEMA ICS1 and IEC The expected environment must be compatible with this rating. When attaching wall-mountable controllers to their mounting surfaces, use fasteners rated for the weight of the apparatus (see Table 7 on page 14), the expected shock and vibration of the installation, and the expected environment. Provide sufficient cooling (see Table 8 on page 14) for the expected heat load. Do not mount the controller in direct sunlight or on hot surfaces (Type 1 only). Mount it on a solid, flat surface only. WARNING IMPROPER MOUNTING Before removing the lifting mechanism Ensure that all hardware is of sufficient size and type for the controller weight. Secure and tighten all hardware. Failure to follow this instruction can result in death, serious injury, or equipment damage Schneider Electric All Rights Reserved 13

14 Altivar 58 Split-Box Kit Section 3 Installation 09/2004 SHIPPING WEIGHTS Table 7: Shipping Weight hp Split-Box Kit (lb.) Weight in Pounds 460 Volts 230/208 Volts Power Converter (lb.) Total (lb.) Split-Box Kit (lb.) Power Converter (lb.) Total (lb.) WATTS LOSS/HEAT DISSIPATION DATA The total dissipated watts loss is provided strictly for sizing the environmental HVAC cooling requirements based upon worst case operating conditions. Table 8: Total Watts Loss hp Split-Box Kit (W) 460 Volts 230/208 Volts Power Converter (W) Total (W) NOTE: For BTU/hr, multiply values by Split-Box Kit (W) Power Converter (W) Total (W) Schneider Electric All Rights Reserved

15 Altivar 58 Split-Box Kit 09/2004 Section 3 Installation DIMENSIONS AND WEIGHTS FOR WALL OR PANEL MOUNTING Figure 4: Mounting Information for Vac; /230 Vac Top View with Power Converter (310) (355) 7.40 (188) (530) 1.12 (29) 1.88 (48) 0.53 (14) (864) (844) 6.76 (172) 9.03 (229) 8.75 (222) 5.00 (127) Four Radius (8) Slots Two 0.50 x 2.00 (13 x 51) Lifting Slots ISO View without Power Converter 8.13 (206) Left Side View with Power Converter 0.25 (6) 1.43 (36) 6.00 (1.52) Front View with Power Converter 8.00 (203) Dimension: in. (mm) 2.00 (51) 1.78 (45) 1.81 (46) 9.03 (229) 1.81 (46) Bottom View 1.81 (46) Four Concentric Knockouts for 0.50 (13), 0.75 (19), and 1.00 (25) Conduit Hubs 0.00 (0) Mounting Clearance 2004 Schneider Electric All Rights Reserved 15

16 Altivar 58 Split-Box Kit Section 3 Installation 09/2004 Figure 5: Mounting Information for Vac; /230 Vac Top View with Power Converter (310) (353) 8.38 (213) 1.26 (32) 2.37 (60) 0.58 (15) 9.06 (230) (292) (286) 6.50 (165) Four Radius (8) Slots (603) (1067) (1046) Two 0.50 x 2.00 (13 x 51) Lifting Slots ISO View without Power Converter (268) Left Side View with Power Converter 0.22 (6) 1.68 (43) 8.00 (203) Front View with Power Converter 8.00 (203) Dimension: in. (mm) 2.00 (51) 1.82 (46) 2.64 (67) 3.39 (86) (292) 1.89 (48) Bottom View Four Concentric Knockouts for 0.50 (13), 0.75 (19), and 1.00 (25) Conduit Hubs 0.00 (0) Mounting Clearance Schneider Electric All Rights Reserved

17 Altivar 58 Split-Box Kit 09/2004 Section 3 Installation WIRE ROUTING AND INTERCONNECTION Wire Class Noise Class Quiet Wiring 1 (QW1) Quiet Wiring 2 (QW2) Standard Wiring 1 (SW1) Standard Wiring 2 (SW2) Standard Wiring 3 (SW3) Pulse Wiring 1 (PW1) Voltage Class The wire class describes the compatibility of the field wiring terminal with the conductor material and insulation system. When used in conjunction with the required conductor current rating and the controller ambient temperature rating, the wire class forms the basis for selecting a conductor size that limits the temperature on the conductor insulation at the field wiring terminal to acceptable limits. Conductors with operating temperatures exceeding those given by the wire class can be used, but the conductor size must be selected based on the wire class limits. The noise class categorizes the electromagnetic properties of the voltages and currents present. The six noise class categories determine proper wiring methods and physical segregation. High-susceptibility analog and digital control signals. Signals falling under this classification include digital communication/network circuits, controller analog I/O, and analog process signals. Medium-susceptibility analog and digital control signals. Signals falling under this classification include 24 Vdc and 24 Vac control circuits. Low-susceptibility control or power circuits rated less than 600 Vac (250 Vdc) and less than 15 A (voltage and current spectra are generally contained within khz). Signals falling under this classification include 120 Vac control circuits. Power circuits rated greater than 15 A (voltage and current spectra are generally contained within khz). Signals falling under this classification include line power to controllers. Reserved. Control or power circuits whose voltage or current spectra significantly exceed 9 khz. Signals falling under this classification include motor and dynamic braking circuits fed from PWM power converters. The voltage class groups the voltages present into recognized conductor insulation categories (30, 150, 300, and 600 V) for selection of conductor insulation voltage rating and physical segregation purposes Schneider Electric All Rights Reserved 17

18 Altivar 58 Split-Box Kit Section 3 Installation 09/2004 Wiring Methods Based upon the Noise Class and Voltage Class of the conductors, apply the wiring methods in Table 9 to the drive system. Table 9: Wire Routing and Interconnection Wiring Methods and Considerations Noise Class of Conductors [1] QW1 QW2 SW1 SW2 PW1 Conductor Grouping in Wireways and Conduits 1. Bundle all conductors of 1- or 3-phase AC power circuits to minimize stray magnetic fields. X X X 2. Bundle all conductors of a DC power circuit to minimize stray magnetic fields. X X X 3. When paralleled conductors must be run in separate wireways or conduit, bundle conductors into groups that minimize stray magnetic fields. X X 4. Maintain conductor runs that are as short and direct as is practical. X X X X X Separation of Circuits 1. DO NOT run different noise class conductors in the same conduit. X X X X X 2. DO NOT run different voltage class conductors in the same conduit unless all conductors are insulated for the maximum voltage class present. X X X X X 3. All PW conductor groups must be individually separated using metallic conduit. X 4. Separate all conductors by Noise Class. Use the following circuit separation when conductors can run parallel for more than 12 inches. Metallic conduit: 3 in. from QW to SW or PW X X X X X Metallic tray: 3 in. from SW to PW X X X Metallic tray: 6 in. from QW to SW or PW X X X X X Against continuous metal surface: 3 in. from SW to PW X X X Against continuous metal surface: 6 in. from QW to SW or PW X X X X X Metallic conduit housing QW: 12 in. to non-metallic conduit SW or PW X X X X X Non-metallic conduit: 3 in. from SW to PW X X X Non-metallic conduit: 24 in. from QW to SW or PW X X X X X 5. If QW and SW1 wiring must cross SW2 or PW1 wiring, cross the bundles at right angles. X X X X X Common Mode Noise Issues 1. Provide adjacent signal returns using twisted pair cable. X X 2. Galvanically isolate the signal and the associated signal return path when possible. X X Shielding 1. Use metallic conduit for all power and control circuits external to the controller enclosure. X X X X X 2. Use shields that are continuous and equipped with a drain wire. X X X 3. DO NOT group different noise class conductors within the same shield. X X X X X 4. Minimize the non-shielded portion of the conductor at the ends of the shielded cable. X X X X X 5. When shielding AC or DC power conductors, group the conductors to minimize the magnetic field in the shield. X X X Grounding 1. Ground shields only at the controller end. X X X X X 2. Use separate ground wire for each shield ground. X X X X X 3. Provide a ground wire with all conductor groups, whether in tray or conduit. X X X 4. When multiple grounds must be made to a shielded power cable, the shield must have the same short circuit withstand capability as the ground conductor in the power cable. X X X 5. Terminate all power grounds and power shield grounds to the controller grounding point or bar. X X X 6. Terminate all signal shield grounds to the terminals provided. X X 7. Always supply a separate equipment grounding conductor with the controller power feed. DO NOT depend upon metallic conduit for the ground connection. X X X [1] X indicates applicability to particular Noise Class Schneider Electric All Rights Reserved

19 Altivar 58 Split-Box Kit 09/2004 Section 3 Installation TERMINAL STRIP LOCATIONS Figures 6 and 7 show the terminal strip locations for Class 8839 Altivar 58 Split-Box Kits. Table 11 lists wire size and terminal torque requirements. Figure 6: Terminal Strip Locations for V and /230 V TB2 Converter Control Connection Terminals TB1 Converter Control Connection Terminals Figure 7: Terminal Strip Locations for V and /230 V TB2 Converter Control Connection Terminals TB1 Converter Control Connection Terminals 2004 Schneider Electric All Rights Reserved 19

20 Altivar 58 Split-Box Kit Section 3 Installation 09/2004 POWER WIRING Table 10: Power Terminal Characteristics Terminal Function Characteristics GND L1 L2 L3 T1 T2 T3 Three-phase power supply (to bottom of circuit breaker) Output connections to motor (from overload relay) 208 Vac ±10% (58S*G2YAA units) 230 Vac ±15% (58S*G3YAA units) 460 Vac ±15% (58S*G4YAA units) 0 to 208 Vac (58S*G2YAA units) 0 to 230 Vac (58S*G3YAA units) 0 to 460 Vac (58S*G4YAA units) The input voltage is connected at the bottom of the circuit breaker, therefore the power terminals have voltage on them at all times, even when the circuit breaker is off. Read and observe the precautions in the following Danger safety message. DANGER VOLTAGE ON TERMINALS WITH DISCONNECTS OFF The terminals under this cover have voltage on them when both disconnects are open. Do not touch the terminals or remove the cover unless the voltage supplying the enclosure is disconnected. Disconnect all power supplying these terminals and the enclosure before working on them. Verify that voltage is off by measurement. Replace the cover on these terminals before applying voltage to the enclosure or to the terminals. Failure to follow these instructions will cause death or serious injury. Table 11: Power Terminal Wire Range Class S_ Terminals Circuit Breaker L1, L2, L3 (Line) Overload Relay T1, T2, T3 (Load) GND Bar GND Lug 208 V 230 V 460 V (AWG) (lb-in) (AWG) (lb-in) (AWG) (lb-in) (AWG) (lb-in) #14 #1/0 50 #18 # / #14 #1/0 50 #14 # / #14 #1/0 50 #10 #1/ / Schneider Electric All Rights Reserved

21 Altivar 58 Split-Box Kit 09/2004 Section 3 Installation CONTROL WIRING The customer terminal block pulls apart to facilitate control wiring. To connect wires to the control terminals, remove the top portion of the terminal block from the base by grasping it and pulling up. See Figure 8. Connect the control wiring to the top portion of the terminal block. Each terminal is rated for one AWG (1.3 to 3.3 mm 2 ) wire or two 16 AWG (1.3 mm 2 ) wires. Torque terminal screws to 5 lb-in (0.6 N m). The customer terminal block is designated TB1 and the power converter control terminal block is designated TB2 on the wiring diagrams shipped with the ATV58 Split-Box Kit. Figure 8: Pull-Apart Customer Terminal Block (TB1) S3 S2 S1A2 A1 Table 12: TB1 Customer Terminal Connections TB1 Customer Terminals SPR Disable (Add Jumper) 1 2 Freeze/Firestat (Remove Jumper/Add in I k) 3 4 Auto Transfer to Bypass Enable (Remove Jumper) 5 6 SPR Disable (Remove Jumper) 7 8 Drive Run Aux. Contact (Closes with drive running motor) 9 10 Bypass Run Aux. Contact (Closes with bypass running motor) Fault Aux. Contact (Contact closes on fault) SPR Coil (120 Vac to energize SPR) ma Input Com (For AI2) S ma Input +DC (For AI2) S2 Shield S1 Auto Start Contact (Auto Mode Run Input) A1 A2 Refer to the power and control circuit elementary diagram in Figure 10 on page Schneider Electric All Rights Reserved 21

22 Altivar 58 Split-Box Kit Section 3 Installation 09/2004 Figure 9: Pull-Apart Converter Control Terminal Block (TB2) S +24 LI4 LI3 LI2 LI1 AI2 +10 AI1 COM R2C R2A R1C R1B R1A S +24 LI4 LI3 LI2 LI1 AI2 +10 AI1 COM R2C R2A R1C R1B R1A Table 13: TB2 Converter Control Terminal Connections TB1 Customer Terminals Drive N.C. Fault Contact R1A Drive N.O. Fault Contact R1B Drive Fault Contact Common R1C Drive N.O. Run Contact R2A Drive Run Contact Common R2C AI1/AI2 D.C. Common COM Speed Potentiometer Input AI1 Speed Potentiometer Supply Voltage ma Input AI2 Drive Run Input LI1 Disabled or Freewheel Stop LI2 Auto/Manual LI3 Forced Local Input LI4 Drive Control Voltage Supply +24 Drive Shield S Schneider Electric All Rights Reserved

23 Altivar 58 Split-Box Kit 09/2004 Section 4 Operation SECTION 4 OPERATION WARNING UNINTENDED EQUIPMENT OPERATION The controller must be programmed. Changes to programming other than the settings shown in Table 14 on page 24 can create incompatibilities with the supplied controller configuration. Read and understand instruction bulletin VVDED397047US, as well as the programming information found on the power and control circuit elementary diagram in Figure 10 on page 28. If the power converter unit is re-initialized using the TOTAL or PARTIAL FACTORY SETTING function, the power converter must be reprogrammed according to the programming instructions found on the power and control circuit elementary diagram in Figure 10 on page 28. If any option card is attached to the power converter, the programming must be reset as shown in Table 14 on page 24. If the power converter unit or the main control board of the power converter is replaced, the power converter must be reprogrammed according to the programming instructions found on the power and control circuit elementary diagram in Figure 10 on page 28. Failure to follow this instruction can result in death, serious injury, or equipment damage. SEQUENCE OF OPERATION AND CONFIGURATION Terminal Command Mode Versus Keypad Command Mode This section describes the basic sequences of operation for the full voltage bypass power circuit configurations and available options. In order for factory-supplied pilot devices and controls to be recognized, the Altivar 58 TRX Drive Controller and Split-Box Kit must be configured to operate in terminal command mode. Enabling the keypad command (KeypadCom) parameter to yes disables certain power converter logic inputs factory-supplied control devices are ignored. For this reason, do not operate the ATV58 controller in the keypad command mode. Before reprogramming logic inputs, outputs, torque types, or control types, consult the factory configuration listing on the power and control circuit elementary diagram in Figure 10 on page 28. Also refer to bulletin VVDED397047US, ALTIVAR 58 Adjustable Speed Drive Controllers Keypad Display VW3A Changing certain factory settings adversely affects the performance of the ATV58 drive controller Schneider Electric All Rights Reserved 23

24 Altivar 58 Split-Box Kit Section 4 Operation 09/2004 Programming the Power Converter NOTE: When a communication or option card is added to the converter, the converter programming must be reentered. The ATV58 power converter must be programmed to match the power and control options available with the ATV58 Split-Box Kit. Configure the following: 1. Select MACRO CFG for variable torque (VT) applications. 2. Then program the functions listed in Table 14 with the indicated settings. Table 14: Power Converter Configuration Menu Code Setting Description Ctl tcc 2W Two-wire control Ctl tct LEL Two-wire control, maintained I-O NST LI2 Freewheel stop I-O RFC LI3 Auto/manual I-O FLO LI4 Forced Local I-O RUN R2 Drive running SEt ACC 10 Acceleration time, in seconds SEt dec 10 Deceleration time, in seconds SEt LSP 3 Low speed, in Hz POWER CIRCUIT Y FULL VOLTAGE BYPASS CAUTION REMOTE OVERLOAD RELAY RESET BURNOUT Do not hold the overload relay reset push button in the ON position. Always push and release the overload relay reset push button (do not hold it down) so that the solenoid ON time is quick and momentary. Failure to follow these instructions can result in solenoid burnout. If burnout occurs, refer to Section 6 on page 31 for the overload relay reset solenoid replacement part. The full voltage bypass package operates the motor either from the power converter or at full-speed, full-voltage line power (bypass mode). You can run the motor in bypass mode in the unlikely event that the power converter becomes inoperative. The bypass package consists of: An IEC-rated isolation and bypass contactor with Class 10 overload relays A power isolation (CAM) switch A 120 V control power transformer (CPT) A thermal magnetic circuit breaker disconnect with means for locking in the open position A bimetallic Class 10 overload relay with remote through-cover push button reset and a 120 V solenoid attached to the overload relay An AFC-OFF-BYPASS switch A HAND-COMM-AUTO switch A manual speed potentiometer. Always set and/or verify that the overload relay is set to the motor full load current. It is necessary to set the CAM switch to 0 (OFF) to isolate the power converter during servicing. See Proper Drive Isolation Method on page Schneider Electric All Rights Reserved

25 Altivar 58 Split-Box Kit 09/2004 Section 4 Operation Operator Controls General Arrangement and Operation Adjustable Speed Operation Bypass Operation Freeze/Firestat Interlocks (if used) Pilot Light Cluster Power Isolation (CAM) Switch Operator controls are located on the front of the ATV58 Split-Box cover. Use the AFC-OFF-BYPASS switch to select either adjustable speed operation of the motor through the power converter (AFC position) or line power operation of the motor (bypass position). The HAND-COMM-AUTO switch and manual speed potentiometer control the operation of the power converter, which is factory configured to operate in terminal command mode (factory default). To control the operation of the motor with the power converter, close the controller disconnect switch located on the front of the ATV58 Split-Box and place the AFC-OFF-BYPASS switch in the AFC position. There are three modes of operation with the HAND-COMM-AUTO switch: HAND mode is for local control. Entering the HAND mode command immediately places the power converter in running mode. In hand mode, use the speed potentiometer mounted on the ATV58 Split-Box to control the speed of the controller. COMM mode is for remote control using a communications card/protocol. If a communications card is not supplied, the COMM mode position acts as the Off position. AUTO mode is for remote control. In AUTO mode, closing a usersupplied run contact between controller terminals TB1-A1 and TB1-A2 immediately places the power converter in running mode. To vary motor speed, adjust the user-supplied auto speed reference signal (4 20 ma) supplied to terminals TB1-S2 (+), TB1-S3 ( ), and TB1-S1 (Shield) in the ATV58 Split-Box. Refer to instruction bulletin VVDED397047US for scaling of this signal. To control the operation of the motor with line power, close the controller disconnect switch located on the front of the ATV58 Split-Box and place the AFC-OFF-BYPASS switch in the bypass position. This transfers motor operation to line power, full speed operation. Moving the selector switch to the off position opens the bypass contactor and stops the motor. Terminals TB1-3 and TB1-4 are dedicated for accepting a user-supplied, normally-closed, freeze/firestat interlock. If the connection between terminals TB1-3 and TB1-4 is opened, the drive output isolation contactor and the drive bypass contactor open, stopping the motor. Remove the factory-installed jumper from these terminals before installing the interlock. This pilot light cluster provides visual indication of protective functions and circuit status. The LED rating is 120 V. The functions of the four pilot lights are: 1. Power on (red): illuminates while mains power is applied to the controller. 2. AFC run (green): illuminates to annunciate a drive run condition. 3. Bypass run (green): illuminates while the bypass contactor coil is energized and the motor is running from line power. 4. AFC fault (yellow): illuminates to annunciate a drive fault condition. This LED normally does not light unless a controller protective circuit causes an abnormal shutdown or the controller is incorrectly programmed. Provides a power isolation (CAM) switch, factory wired between the AC line and the 3% min. line reactor feeding the power converter (L1, L2, and L3) Schneider Electric All Rights Reserved 25

26 Altivar 58 Split-Box Kit Section 4 Operation 09/2004 Line Reactor Smoke Purge Function (Selectable) Automatic Transfer to Bypass Function (Selectable) Auxiliary Drive Run Contact Auxiliary Bypass Run Contact Auxiliary Fault Contact A 3% minimum rated AC line reactor is provided for harmonic mitigation and other power quality benefits. Provides a smoke purge operating mode, controlled by a user-supplied 120 Vac signal applied between terminals TB1-15 and TB1-16. Supplying 120 Vac to TB1-15 and TB1-16 transfers motor operation to line power (if not operating in this mode already). Remove the jumper between terminals TB1-7 and TB1-8, and install it on terminals TB1-1 and TB1-2 to disable the smoke purge function. Enables ATV58 Split-Box full voltage bypass for emergency operation in the event of a power converter fault. Remove the jumper between terminals TB1-5 and TB1-6 to disable the automatic transfer to bypass function. Provides a normally-open (N.O.) contact between terminals TB1-9 and TB1-12 that closes when the bypass contactor is closed and the motor is running in drive mode. Provides a normally-open (N.O.) contact between terminals TB1-11 and TB1-12 that closes when the bypass contactor is closed and the motor is running in bypass mode. Provides a normally-closed (N.C.) fail safe contact between terminals TB1-13 and TB1-14 that closes when the drive faults and the motor either stops or transfers to bypass mode (if enabled) Schneider Electric All Rights Reserved

27 Altivar 58 Split-Box Kit 09/2004 Section 4 Operation PROPER DRIVE ISOLATION METHOD To properly isolate the power converter for service or repair while operating the controller in bypass mode, disconnect all power and observe the precautions on page 13, then remove the cover and switch the power isolation (CAM) switch to position 0 (non-energized path). Before performing any maintenance or service on the controller, read and observe the following precautions. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION This equipment must be installed and serviced only by qualified electrical personnel. Turn off all power supplying this equipment, open the disconnect and lock it in the open position before working on or inside the equipment. Always use a properly-rated voltage-sensing device to confirm that the power is off. Wait three minutes to allow the DC bus to discharge, then verify that the voltage is less than 45 V. Do not operate the disconnect switch or the CAM switch under load with the cover off. Always set the CAM switch to 0 (OFF) before energizing the controller if the power converter leads are removed. Remove the cover plate to install the power converter. Do not discard the cover plate. Keep it for future use. If the power converter is removed for maintenance or service, always install the cover plate and set the CAM switch to 0 (OFF) before energizing the controller. Replace the cover before energizing the controller. Failure to follow these instructions will result in death or serious injury Schneider Electric All Rights Reserved 27

28 Altivar 58 Split-Box Kit Section 4 Operation 09/2004 POWER AND CONTROL CIRCUIT ELEMENTARY DIAGRAM Figure 10: Full Voltage Bypass Package, Power Circuit Y BC (1) (2) BC (3) (4) BC (5) (6) Power CAM Switch 0 1 (2) (1) (4) (3) (6) (5) 3% Minimum AC Line Reactor (A1) (A2) (B1) (B2) (C1) (C2) L1 L2 L3 ATV58H_ Adjustable Frequency Drive U V W IC (5) (6) IC (3) (4) IC (1) (2) R1A R1A IC (83) (84) HAND COMM AUTO Auto Run Contact A1 A2 +24 LI2 LI1 LI3 LI4 +24 LI2 LI1 LI3 LI4 Communications Option Card (If Used) Fault Run +10 AI1 COM AI2 R1C R1B R2A R2A S1 GND R1C R1B R2A R2C +10 AI1 COM S3 S2 S1 IC BC F SPR (53) (54) (53) (54) (4) (12) (13) (14) Drive Run Bypass Run Fault SPR 120 Vac CB L1 L2 L3 Auto Transfer to Bypass Relay Fault Relay Isolation Contactor Remove jumper 7 8 and add jumper 1 2 to disable smoke purge. Fire/freezestat interlocks. Remove jumper. Remove jumper to disable auto transfer to bypass. R1 & R2 are located in the power converter. M Manual Speed Potemtiometer 4 20 ma Input Select MACRO "CFG" for Variable Torque LI1 = Run Forward LI2 = Freewheel Stop LI3 = Auto/Manual LI4 = Forced Local FU2 Detail A (HF) (H1) 460 V FU3 H4 H2 H3 H1 X2 X1 X1 FU1 (X2) (XF) LA7D03F or LAD703F (C1) (C2) OL Reset (13) (14) Power On (X1) (X2) R Drive Run (X1) G (X2) IC (13) (14) R2C (R2C) (R2A) R2A 4 R2 Bypass Run (X1) (X2) G BC (13) (14) 4 Drive Fault (X1) (X2) Y R1B R1 R1C (R1C) (R1B) ATB (2) (7) R1 (R1A) F R1A (13) (14) IC OL (95) (96) TS (A1) (A2) BC (21) (22) F AFC AFC OFF BYP 1 2 (5) (9) (3) 3 (9) (1) SPR ATB (1) 5 6 Bypass Contactor (A1) (A2) IC (21) (22) BYP 2 1 TS BC SPR (5) (H1) FU2 Detail A 208 V (HF) FU3 H2 H1 X1 X2 X1 FU1 (XF) FU2 (HF) (H1) 230 V FU3 H4 H2 H3 H1 X1 X2 X1 FU1 (XF) Schneider Electric All Rights Reserved