C OMMANDERGp LV. Installation Guide. model sizes 1 to kW to 110kW (1HP to 150HP) model sizes 1 to kW to 22kW (0.

Transcription

1 Installation Guide C OMMANDERGp model sizes 1 to kW to 110kW (1HP to 150HP) C OMMANDERGp LV model sizes 1 to kW to 22kW (0.5HP to 30HP) General Purpose Variable Speed Drive for duction motors Part Number: Issue Number: 2

2 General formation The manufacturer accepts no liability for any consequences resultg from appropriate, negligent or correct stallation or adjustment of the optional operatg parameters of the equipment or from mismatchg the variable speed drive (Drive) with the motor. The contents of this Installation Guide are believed to be correct at the time of prtg. In the terests of a commitment to a policy of contuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the Installation Guide, without notice. All rights reserved. No parts of this Installation Guide may be reproduced or transmitted any form or by any means, electrical or mechanical cludg photocopyg, recordg or by any formation-storage or retrieval system, without permission writg from the publisher. Important... Drive software version This product is supplied with the latest version of user-terface and mache-control software. If this product is to be used with other Control Techniques variable speed drives an existg system, there may be some differences between their software and the software this product. These differences will cause a difference functions. This may also apply to variable speed drives returned from a Control Techniques Service Centre. If there is any doubt, contact a Control Techniques Drive Centre. Copyright Author: Issue Code: March 2000 Control Techniques Drives Ltd RFD gpiu2 Issue Date: March 2000 S/W Version: 03.XX.XX

3 Contents Chapter 1 Safety Information Warngs, Cautions and Notes Electrical safety general warng System design Environmental limits Compliance with regulations Safety of personnel Risk analysis Motor Adjustg parameters Installg the Drive Environmental requirements EMC considerations Planng the stallation Calculatg the enclosure size Installg the Drive and RFI filter Power connections Wirg recommendations Variations the EMC wirg recommendations Signal connections 2-41 Appendix A Motor Connections A-1 A.1 Cable length A-1 A.2 Multiple motors A-1 B UL Listg Information B-1 B.1 AC supply specification B-1 B.2 Maximum contuous output current B-1 C Data C-1 C.1 Drive C-1 C.2 Optional RFI filters C-7 Issue code: gpiu2 i

4 Declaration of Conformity Control Techniques Limited The Gro Newtown Powys UK SY16 3BE These products comply with the Low Voltage Directive 73/23/EEC, the Electromagnetic Compatibility (EMC) Directive 89/336/EEC and the CE Markg Directive 93/68/EEC. GPD 1401 GPD 1402 GPD 1403 GPD 1404 GPD 1405 GPD 2401 GPD 2402 GPD 2403 GPD 3401 GPD 3402 GPD 3403 GPD 3404 GPD 3405 GPD 4401 GPD 4402 GPD 4403 GPD 4404 GPD 4405 GPD 1201 GPD 1202 GPD 1203 GPD 1204 GPD 1205 GPD 2201 GPD 2202 GPD 2203 GPD 3201 GPD 3202 GPD 3203 GPD 3204 The AC variable speed drive products listed above, have been designed and manufactured accordance with the followg European harmonised, national and ternational standards: EN60249 IEC326-1 IEC326-5 IEC326-6 IEC664-1 EN60529 UL94 UL508C EN EN EN EN Base materials for prted circuits Prted boards: general formation for the specification writer Prted boards: specification for sgle- and double-sided prted boards with plated-through holes Prted boards: specification for multilayer prted boards Insulation co-ordation for equipment with low-voltage systems: prciples, requirements and tests Degrees of protection provided by enclosures (IP code) Flammability ratg of plastic materials Standard for power conversion equipment Generic emission standard for the residential, commercial and light dustrial environment Generic emission standard for the dustrial environment Generic immunity standard for the dustrial environment Adjustable speed electrical power drive systems Part 3: EMC product standard cludg specific test methods W. Drury Executive VP Technology Newtown Date: 13th March 2000 These electronic Drive products are tended to be used with appropriate motors, controllers, electrical protection components and other equipment to form complete end products or systems. Compliance with safety and EMC regulations depends upon stallg and configurg Drives correctly, cludg usg the specified put filters. The Drives must be stalled only by professional assemblers who are familiar with requirements for safety and EMC. The assembler is responsible for ensurg that the end product or system complies with all the relevant laws the country where it is to be used. Refer to the Installation Guide. A Commander GP EMC Data Sheet is also available givg detailed EMC formation. 1 Conducted emission sizes 1 to 3, not size 4. See the relevant EMC Data Sheet. ii Issue code: gpiu2

5 1 Safety Information 1.1 Warngs, Cautions and Notes A Warng contas formation which is essential for avoidg a safety hazard. A Caution contas formation which is necessary for avoidg a risk of damage to the product or other equipment. A Note contas formation which helps to ensure correct operation of the product. 1.2 Electrical safety general warng 1.4 Environmental limits Instructions this Installation Guide regardg transport, storage, stallation and use of Drives must be complied with, cludg the specified environmental limits. Drives must not be subjected to excessive physical force. 1.5 Compliance with regulations The staller is responsible for complyg with all relevant regulations, such as national wirg regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses or other protection, and protective earth (ground) connections. This Installation Guide contas structions for achievg compliance with specific EMC standards. The voltages used the Drive can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when workg with or adjacent to the Drive. Specific warngs are given at the relevant places this Installation Guide and the accompanyg User Guide. The stallation must comply with all relevant safety legislation the country of use. 1.3 System design The Drive is tended as a component for professional corporation to complete equipment or systems. If stalled correctly the Drive may present a safety hazard. The Drive uses high voltages and currents, carries a high level of stored electrical energy, and is used to control mechanical equipment which can cause jury. Close attention is required to the electrical stallation and the system-design to avoid hazards either normal operation or the event of equipment malfunction. System-design, stallation, commissiong and matenance must be carried out by personnel who have the necessary trag and experience. They must read this safety formation and this Installation Guide carefully. To ensure mechanical safety, additional safety devices such as electro-mechanical terlocks may be required. The Drive must not be used a safetycritical application without additional high-tegrity protection agast hazards arisg from a malfunction. With the European Union, all machery which this product is used must comply with the followg directives: 98/37/EC: Safety of Machery 89/336/EEC: Electromagnetic Compatibility. 1.6 Safety of personnel The STOP function of the Drive does not remove dangerous voltages from the output of the Drive or from any external option unit. The Stop and Start controls or electrical puts of the Drive must not be relied upon to ensure safety of personnel. If a safety hazard could exist from unexpected startg of the Drive, an terlock that electrically isolates the Drive from the AC supply must be stalled to prevent the motor beg advertently started. Careful consideration must be given to the functions of the Drive which might result a hazard, either through their tended functions (eg. Auto-start) or through correct operation due to a fault or trip (eg. stop/start, forward/reverse, maximum speed). Under certa conditions, the Drive can suddenly discontue control of the motor. If the load on the motor could cause the motor speed to be creased (eg. hoists and cranes), a separate method of brakg and stoppg the motor must be used (eg. a mechanical brake). Issue code: gpiu2 Safety Information 1-1

6 Before connectg the AC supply to the Drive, it is important that you understand the operatg controls and their operation. If doubt, do not adjust the Drive. Damage may occur, or lives put at risk. Carefully follow the structions this Installation Guide. Before makg adjustments to the Drive, ensure all personnel the area are warned. Make notes of all adjustments that are made. 1.7 Risk analysis In any application where a malfunction of the Drive could lead to damage, loss or jury, a risk analysis must be carried out, and where necessary, further measures taken to reduce the risk. This would normally be an appropriate form of dependent safety back-up system usg simple electromechanical components. 1.8 Motor Ensure the motor is stalled accordance with the manufacturer s recommendations. Ensure the motor shaft is not exposed. Standard squirrel-cage duction motors are designed for sgle-speed operation. If it is tended to use the capability of the Drive to run a motor at speeds above its designed maximum, it is strongly recommended that the manufacturer is consulted first. Low speeds may cause the motor to over-heat because the coolg fan becomes less effective. The motor should then be fitted with a protection thermistor. If necessary, a separate coolg fan should be used. If a Drive is to be used to control a number of motors, special measures need to be taken to ensure protection of the motors; refer to Motor protection Appendix A Motor Information. 1.9 Adjustg parameters 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 controlled system. Measures must be taken to prevent unwanted changes due to error or tamperg. 1-2 Safety Information Issue code: gpiu2

7 2 Installg the Drive Warng Warng Adhere to the structions The mechanical and electrical stallation structions must be adhered to. Any questions or doubt should be referred to the supplier of the equipment. It is the responsibility of the owner or user to ensure that the stallation of the Drive and any external option unit, and the way which they are operated and mataed, comply with the requirements of the Health and Safety at Work Act the United Kgdom or applicable legislation and regulations and codes of practice the country which the equipment is used. Competence of the staller The Drive must be stalled only by professional assemblers who are familiar with the requirements for safety and EMC. The assembler is responsible for ensurg that the end-product or system complies with all the relevant laws the country where it is to be used. 2.1 Environmental requirements Warng Warng Warng Warng Authorized access The enclosure should prevent access by anyone except for authorized, traed service personnel. Fire enclosure The Drive case is not classified as a fire enclosure. When this protection is required, the Drive should be stalled a fire enclosure. Hazardous areas The Drive must not be located a classified hazardous area unless the Drive is stalled an approved enclosure and the stallation is certified. Before a Commander GP size 3 or 4 is used as a motorg Drive a Regen application, the Drive must be modified. Contact the supplier of the Drive for details. 1. Refer to Appendix C Data for details of the environmental requirements. 2. If condensation is likely to occur when the Drive is not use, an anti-condensation heater must be stalled. This heater must be switched off when the Drive is use; automatic switchg is recommended. 3. If the Drive is to be mounted directly above any heat-generatg equipment (such as another Drive), the maximum temperature of the air immediately below the Drive should be taken as the ambient temperature for the Drive. Warng Installation an enclosure The Drive must be protected agast water, condensation and electrically conductive contamation. When the gland plate and appropriate glands are fitted, the Drive can atta gress protection to NEMA 1 and IP40 ( accordance with IEC529). UL listg is valid when the Drive is stalled a type 1 enclosure as defed UL If the Drive is to be mounted beneath other equipment, such as another Drive, the Drive should not cause the ambient temperature requirements of the equipment to be exceeded. 5. When compliance with EMC emission standards is required, the enclosure must be made of metal but does not require special EMC features. UL-listg requirements are given Appendix B. Issue code: gpiu2 Installg the Drive 2-1

8 2.2 EMC considerations Dependg on the requirements of the stallation, one of the followg levels of electromagnetic compatibility (EMC) should be adopted: Route EMC precautions These precautions are recommended when strict compliance with emission standards is not required. The risk of disturbg adjacent electronic equipment is mimized by adoptg these precautions. Compliance with EMC emission standards These precautions are recommended when strict compliance with emission standards is required. In addition, it is recommended that these precautions are taken when the Drive is stalled a residential area, or adjacent to sensitive electronic equipment such as radio receivers or similar. Compliance with EN (standard for Power Drive Systems) Meetg the requirements of this standard depends on the environment that the Drive is tended to operate, as follows: Operation the first environment Observe the guideles given Compliance with EMC emission standards. An RFI filter will always be required. Some model sizes may require additional filterg techniques to be applied. Operation the second environment An RFI filter may not be required. Follow the guideles given Route EMC precautions or Compliance with EMC emission standards dependg on the requirements of the end user. Caution The second environment typically cludes an dustrial low-voltage power supply network which does not supply buildgs used for domestic purposes. Operatg the Drive this environment without an RFI filter may cause terference to nearby electronic equipment whose sensitivity has not been appreciated. The user must take remedial measures if this situation arises. If the consequences of unexpected disturbances are severe, it is recommended that the emission limits of EN be adhered to. Instructions are given later this chapter for these levels of EMC. Refer to Appendix C Data for further formation on compliance with EMC standards and defitions of environments. Detailed structions and EMC formation are given the Commander GP EMC Data Sheet which is available from the Drive Centres and distributors listed at the end of the User Guide. Compliance data is given Appendix C Data. Note The staller of the Drive is responsible for ensurg compliance with the EMC regulations that apply where the Drive is to be used. The Drive will comply with the standards for emission, such as EN , only when the structions given Planng the stallation and Wirg recommendations later this chapter are followed closely. Warng Special consideration is needed if the filter is to be used movable equipment where the ground is connected through a flexible cable and plug/socket. Additional measures such as a supplementary ground connection or ground contuity monitorg will be required. 2-2 Installg the Drive Issue code: gpiu2

9 2.3 Planng the stallation Instructions numbered steps The structions this section are contaed numbered steps. In some of these steps you will need to make a note of a value for future reference and, to help with identification, the number of the step. AC supply protection Warng STEP 1 Note The AC supply to the Drive must be fitted with suitable protection agast overload and short-circuits. Table 2 1 shows recommended fuse ratgs. Failure to observe this recommendation will cause a risk of fire. Include a fuse of the specified ratg each phase of the AC supply. The use of the followg types of fuse is recommended: Europe: Type gg HRC dustrial fuses to IEC 269 (BS88) USA: RK1 600VAC An MCB or MCCB havg the correct thermal and magnetic trip ratgs may be used place of fuses, on condition the fault-current clearg capacity is sufficient for the stallation. UL listg is dependent on the use of the correct type of UL-listed fuse, and applies when the symmetrical short-circuit current does not exceed 5kA for model sizes 1 to 3, and 10kA for model size 4. Refer to Appendix B UL Listg Information. Table 2 1 Fuse ratgs for Commander GP and LV Model Fuse ratg Model Fuse ratg GPD 1201 GPD 1401 GPD 1202 GPD 1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 GPD 2201 GPD 2401 GPD 2202 GPD 2402 GPD 2203 GPD 2403 Power cables Warng Cable type and size STEP 2 6A GPD 3201 GPD A 10A GPD A 10A GPD 3202 GPD A GPD 3203 GPD A GPD 3204 GPD A 70A 80A 16A GPD A 20A GPD A 35A GPD A GPD 4404 GPD A 250A Wirg must be accordance with local regulations and codes of practice. The table below shows typical cable sizes for power put and output wirg. In the event of a conflict, local regulations prevail. For the followg power connections... AC supply to RFI filter (when used) AC supply (or RFI filter) to Drive Drive to motor Drive to brakg resistor... use 105 C (221 F) pvc-sulated cable of suitable voltage ratg and havg copper conductors, as shown Table 2 2. Issue code: gpiu2 Installg the Drive 2-3

10 Table 2 2 Cable sizes Motor cable Model GPD 1201 GPD 1401 GPD 1202 GPD 1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 GPD 2201 GPD 2401 GPD 2202 GPD 2402 GPD 2203 GPD 2403 GPD 3201 GPD 3401 Cable size 1.5 mm 2 16 AWG 2.5 mm 2 14 AWG 2.5 mm 2 14 AWG 2.5 mm 2 14 AWG 2.5 mm 2 14 AWG 2.5 mm 2 14 AWG 4 mm 2 10 AWG 4 mm 2 10 AWG 6 mm 2 8 AWG GPD mm 2 6 AWG GPD 3202 GPD 3403 GPD 3203 GPD 3404 GPD 3204 GPD mm 2 6 AWG 16 mm 2 4 AWG 25 mm 2 4 AWG GPD mm 2 2 AWG GPD mm 2 2 AWG GPD mm 2 0 AWG GPD mm 2 2/0 AWG GPD mm 2 3/0 AWG When EMC emission requirements are to be met, shielded cable or steel wire armoured cable may be required for the followg: AC supply to enclosure Drive to motor Drive to brakg resistor when part of the cable is outside the enclosure For further details, see Wirg guideles later this chapter. STEP 3 Sce capacitance the motor cable causes loadg on the output of the Drive, ensure the cable length does not exceed the values given Table 2 3. Table 2 3 Nomal AC supply voltage Maximum cable lengths for Commander GP 400V 480V Model Maximum cable length * (PWM switchg frequency at 3kHz) GPD 1201 GPD 1401 GPD 1202 GPD 1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 GPD 2201 ~ GPD 2203 GPD 2401 ~ GPD 2403 GPD 3201 ~ GPD 3204 GPD 3401 ~ GPD 3405 GPD 4401 ~ GPD 4405 m ft m ft * Cable lengths excess of the specified values may be used only when special techniques are adopted; refer to the supplier of the Drive. 2-4 Installg the Drive Issue code: gpiu2

11 The maximum cable length is reduced from that shown the table under the followg conditions: PWM switchg frequency exceedg 3kHz model sizes 3 and 4 The maximum cable length is reduced proportion to the crease PWM switchg frequency, eg. at 9kHz, the maximum length is 1 / 3 of that shown. High-capacitance cables Most cables have an sulatg jacket between the cores and the armour or shield; these cables have a low capacitance and are recommended. Cables that do not have an sulatg jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted the table. (Figure 2 1 shows how to identify the two types.) Note If the isolator switch is closed when the Drive is enabled, the Drive may trip. When EMC compliance is required, refer to Variations the EMC wirg recommendations later this chapter. Output current, PWM switchg frequency, Ambient temperature Thermal protection Note The Drive can supply the rated current up to an ambient temperature of 40 o C (104 F) (dependg on the PWM switchg frequency used). Normal capacitance Shield or armour separated from the cores High capacitance Shield or armour close to the cores The Drive can be operated an ambient temperature up to 50 o C (122 o F) at de-rated output current. In this case, ensure the value of parameter 0.46 Motor rated current does not exceed the value given Table 2-4. Figure 2 1 Cable construction fluencg the capacitance Multiple motors Special requirements apply when the Drive is to control more than one motor. Refer to Appendix A Motor Connections. Isolator switch the motor cable An isolator switch may be connected the motor cable for safety purposes. Refer to the followg Warng and Note. Warng The isolator switch must not be operated when the Drive is enabled. (If an AC-rated switch is used and the Drive is producg a low output frequency when the switch is opened, severe arcg can occur which will prevent the switch from breakg the circuit.) A suitable terlock arrangement can be used, such as an isolator switch fitted with additional contacts that open before the ma contacts. These additional contacts should be used to disable the Drive. The Drive has two forms of thermal protection for the power output stage (IGBT bridge), as follows: 1. A thermistor mounted on the heatsk monitors the heatsk temperature. If this exceeds 95 C (203 F), the thermistor will cause the Drive to trip. The display will dicate Oh2. 2. Intelligent thermal modellg estimates (by calculation) the junction temperature of the IGBTs. There are two temperature thresholds which cause the followg to occur: If the first threshold is reached, the PWM switchg frequency is halved order to reduce dissipation the IGBTs. (When the frequency is halved, the value of parameter 0.41 PWM switchg frequency remas at the value set by the user; if the frequency is 3kHz or 4.5kHz, no halvg occurs). Then at one second tervals, the Drive will attempt to restore the origal PWM switchg frequency. This will be successful if the estimated temperature has reduced sufficiently. If the estimated temperature has contued to rise and reaches a second threshold, the Drive will trip. The display will dicate Oh1. Issue code: gpiu2 Installg the Drive 2-5

12 STEP 4 Note that the Drive can deliver an overload current up to 150% of the rated current for 60 seconds Refer to Table 2 4 to fd the maximum contuous output current that can be obtaed for the required ambient temperature and PWM switchg frequency. The maximum ambient temperature can be 40 C or 50 C (104 F or 122 F). Note that the nomal power ratg of the Drive may not be achieved above 40 C (104 F). Caution Operation a maximum ambient temperature of 50 C (122 F) Unless the precaution described here is taken, the Drive will limit the maximum contuous output current only to the value for 40 C, (104 F) and not to the value stated Table 2 4 for 50 C (122 F). Make a note of the value for 50 C (122 F); you will need to refer to it when you reach Configurg the Drive for the motor Chapter 2 of the User Guide. At that pot, ensure that the value to be entered parameter 0.46 Motor rated current does not exceed the noted value. Make a note of this step number and the followg: Chosen maximum ambient temperature. Chosen PWM switchg frequency for each Drive. From Table 2 5, the maximum power dissipation (heat) figure (P DISS ) at the chosen PWM switchg frequency for each Drive (this figure is the total power dissipation at the maximum contuous output current available at the chosen PWM switchg frequency, and cludes power dissipated option modules when fitted). If the maximum ambient temperature will be 50 C (122 F), note the value of the maximum permissible output current obtaed from Table 2 4. This will be the maximum value that parameter 0.46 Motor rated current should be set at. 2-6 Installg the Drive Issue code: gpiu2

13 Table 2 4 Maximum permissible contuous output current 40 C (104 F) ambient GPD 1201 GPD 1401 GPD 1202 GPD 1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 Nomal ratg Maximum permissible contuous output current Model 380V 460V 3kHz 4.5kHz 6kHz 9kHz 12kHz 0.37 kw 0.75 kw 0.55 kw 1.1 kw 0.75 kw 1.5 kw 1.1 kw 2.2 kw 2.2 kw 4.0 kw 0.5 HP 1.0 HP 0.75 HP 1.5 HP 1.0 HP 2.0 HP 1.5 HP 3.0 HP 3.0 HP 5.0 HP 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A 3.8 A 3.8 A 3.8 A 3.8 A 3.8 A 5.6 A 5.6 A 5.6 A 5.6 A 4.5 A 9.5 A 9.5 A 8.5 A 7.0 A 5.5 A GPD 2201 GPD kw 5.5 kw 4.0 HP 7.5 HP 12.0 A 12.0 A 12.0 A 12.0 A 11.7 A GPD 2202 GPD kw 7.5 kw 5.0 HP 10 HP 16.0 A 16.0 A 16.0 A 14.2 A 11.7 A GPD 2203 GPD kw 11.0 kw 7.5 HP 15 HP 25.0 A 21.7 A 18.2 A 14.2 A 11.7 A GPD 3201 GPD kw 15.0 kw 10 HP 20 HP 34.0 A 34.0 A 34.0 A 28.0 A 23.0 A GPD kw 25 HP 40.0 A 40.0 A 37.0 A 28.0 A 23.0 A GPD 3202 GPD 3403 GPD 3203 GPD 3404 GPD 3204 GPD kw 22.0 kw 15.0 kw 30.0 kw 22.0 kw 37.0 kw 15 HP 30 HP 20 HP 40 HP 30 HP 50 HP 46.0 A 46.0 A 40.0 A 32.0 A 26.6 A 60.0 A 47.0 A 40.0 A 32.0 A 26.7 A 74.0 A 70.0 A 56.0 A 46.0 A 35.0 A 28.0 A GPD kw 75 HP 96 A 96 A 88 A 70 A GPD kw 100 HP 124 A 104 A 88 A 70 A GPD kw 125 HP 156 A 124 A 105 A 80 A GPD kw 150 HP 180 A 175 A 145 A 110 A GPD kw 150 HP 202 A 175 A 145 A 110 A Issue code: gpiu2 Installg the Drive 2-7

14 50 C (122 F) ambient GPD 1201 GPD 1401 GPD 1202 GPD 1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 Nomal ratg Maximum permissible contuous output current Model 380V 460V 3kHz 4.5kHz 6kHz 9kHz 12kHz 0.37 kw 0.75 kw 0.55 kw 1.1 kw 0.75 kw 1.5 kw 1.1 kw 2.2 kw 2.2 kw 4.0 kw 0.5 HP 1.0 HP 0.75 HP 1.5 HP 1.0 HP 2.0 HP 1.5 HP 3.0 HP 3.0 HP 5.0 HP 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A 3.8 A 3.8 A 3.8 A 3.8 A 3.3 A 5.6 A 5.6 A 5.1 A 4.0 A 3.3 A 6.9 A 5.9 A 5.1 A 4.0 A 3.3 A GPD 2201 GPD kw 5.5 kw 4.0 HP 7.5 HP 12.0 A 12.0 A 12.0 A 11.6 A 9.7 A GPD 2202 GPD kw 7.5 kw 5.0 HP 10.0 HP 16.0 A 16.0 A 14.7 A 11.6 A 9.7 A GPD 2203 GPD kw 11.0 kw 7.5 HP 15.0 HP 20.0 A 17.3 A 14.7 A 11.6 A 9.7 A GPD 3201 GPD kw 15.0 kw 10.0 HP 20.0 HP 34.0 A 34.0 A 28.0 A 21.0 A 17.9 A GPD kw 25.0 HP 40.0 A 34.0 A 28.0 A 21.0 A 17.9 A GPD 3202 GPD 3403 GPD 3203 GPD 3404 GPD 3204 GPD kw 22.0 kw 15.0 kw 30.0 kw 22.0 kw 37.0 kw 15.0 HP 30.0 HP 20.0 HP 40.0 HP 30.0 HP 50.0 HP 44.0 A 36.0 A 31.0 A 24.0 A 20.6 A 44.0 A 36.0 A 31.0 A 24.0 A 20.9 A 50.0 A 41.0 A 34.0 A 26.0 A 23.0 A GPD kw 75HP 95 A 85 A 75 A 60 A GPD kw 100HP 105 A 85 A 75 A 60 A GPD kw 125 HP 135 A 105 A 85 A 65 A GPD kw 150 HP 180 A 150 A 125 A 95 A GPD kw 150 HP 190 A 150 A 125 A 95 A 2-8 Installg the Drive Issue code: gpiu2

15 Table 2 5 Model GPD 1201 GPD 1401 GPD 1202 GPD 1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 Maximum total power dissipation Nomal ratg Maximum total power dissipation 380V 460V 3kHz 4.5kHz 6kHz 9kHz 12kHz 0.37 kw 0.75 kw 0.55 kw 1.1 kw 0.75 kw 1.5 kw 1.1 kw 2.2 kw 2.2 kw 4.0 kw 0.5 HP 1.0 HP 0.75 HP 1.5 HP 1.0 HP 2.0 HP 1.5 HP 3.0 HP 3.0 HP 5.0 HP 80 W 80 W 90 W 90 W 90 W 90 W 90 W 100 W 100 W 110 W 100 W 110 W 110 W 120 W 130 W 130 W 130 W 140 W 150 W 150 W 180 W 190 W 190 W 190 W 170 W GPD 2201 GPD kw 5.5 kw 4.0 HP 7.5 HP 210 W 230 W 250 W 280 W 310 W GPD 2202 GPD kw 7.5 kw 5.0 HP 10 HP 270 W 290 W 310 W 320 W 310 W GPD 2203 GPD kw 11.0 kw 7.5 HP 15 HP 400 W 380 W 360 W 330 W 310 W GPD 3201 GPD kw 15.0 kw 10 HP 20 HP The default PWM switchg frequency is 3kHz 570 W 620 W 670 W 660 W 630 W GPD kw 25 HP 660 W 720 W 730 W 660 W 630 W GPD 3202 GPD 3403 GPD 3203 GPD 3404 GPD 3204 GPD kw 22.0 kw 15 kw 30.0 kw 22 kw 37.0 kw 15 HP 30 HP 20 HP 40 HP 30 HP 50 HP 730 W 800 W 770 W 730 W 700 W 950 W 830 W 790 W 740 W 710 W 1090 W 990 W 920 W 850 W 800 W GPD kW 75 HP 1460 W 1610 W 1630 W 1530 W GPD kw 100 HP 1910 W 1780 W 1670 W 1560 W GPD kw 125 HP 2370 W 2130 W 2030 W 1860 W GPD kw 150 HP 2640 W 2890 W 2700 W 2470 W GPD kw 150 HP 2970 W 2910 W 2720 W 2490 W Issue code: gpiu2 Installg the Drive 2-9

16 Usg an RFI filter STEP 5 For compliance with the emission standards such as EN or EN , use the recommended RFI filter as shown Table 2 6. Use one RFI filter for each Drive. (Standards that are met are specified Appendix C Data) Make a note of this step number and the followg for each filter to be used: Size code or part number Maximum power dissipation figure IP ratg Table 2 6 Model GPD 1201 GPD 1401 GPD 1202 GPD1402 GPD 1203 GPD 1403 GPD 1204 GPD 1404 GPD 1205 GPD 1405 GPD 2201 GPD 2401 GPD 2202 GPD 2402 GPD 2203 GPD 2403 GPD 3201 GPD 3401 RFI filter data Size Part number RFI filter Maximum power dissipation (W) IP ratg A IP20 A IP20 A IP20 A IP20 A IP20 B IP20 B IP20 B IP20 C IP00 GPD 3402 C IP00 GPD 3202 GPD 3403 GPD 3203 GPD 3404 GPD 3204 GPD 3405 C IP00 D IP00 D IP00 Model size 1 When the motor cable is to exceed 50m (165 feet), use RFI filter size B ( ). Usg a brakg resistor Note When a brakg resistor is used the Drive should be operated FAST ramp mode. The Drive will not follow the deceleration ramp set if this mode is not used. Brakg occurs when the Drive is deceleratg the motor, or is preventg the motor from gag speed due to mechanical fluences. Durg brakg, energy is returned to the Drive by the motor. When the motor is beg braked by the Drive, the maximum regenerated power that the Drive can absorb is equal to the power dissipation (losses) of the Drive. When the regenerated power is likely to exceed these losses, a brakg resistor must be connected. By default, the Drive brakes the motor under PI control which extends the deceleration time as necessary order to keep the DC bus at a constant voltage. The method of brakg can be changed; if required. Housg the resistor, and routg the connectg cable Warng Warng High temperatures Brakg resistors can reach high temperatures. Locate brakg resistors so that damage cannot result. Use cable havg sulation capable of withstandg high temperatures. Overload protection It is essential that an overload protection device is corporated the brakg resistor circuit; this is described Protection circuit for an optional brakg resistor STEP 8. GPD 4401 E IP00 GPD 4402 F IP00 GPD 4403 F IP00 GPD 4404 F IP00 GPD 4405 H IP Installg the Drive Issue code: gpiu2

17 STEP 6 When a brakg resistor is to be mounted outside the enclosure, ensure that it is mounted a ventilated metal housg that will perform the followg functions: Prevent advertent contact with the resistor Allow adequate ventilation for the resistor When compliance with EMC emission standards is required, external connection requires the cable to be armoured or shielded, sce it is not fully contaed a metal enclosure. Internal connection does not require the cable to be armoured or shielded. Mimum resistances and power ratgs Table 2 7 Model GPD GPD 1205 GPD 1401 ~ GPD 1405 GPD 2201 GPD 2401 GPD 2202, GPD 2203 GPD 2402, GPD 2403 GPD GPD 3204 GPD 3401 ~ GPD 3405 Mimum resistance values and peak power ratg for the brakg resistor at 40 C (104 F) Mimum resistance 20 Ω 40Ω 20 Ω 40Ω 15 Ω 30Ω 5 Ω 10Ω Instantaneous power ratg 15kW 15kW 20kW 60kW GPD 4401 ~ GPD Ω 120kW The mimum resistance allows the brakg resistor to dissipate up to approximately 150% of the power ratg of the Drive for up to 60 seconds. For high-ertia loads or under contuous brakg, the contuous power dissipated the brakg resistor may be as high as the power ratg of the Drive. The total energy dissipated the brakg resistor is dependent on the amount of energy to be extracted from the load. The stantaneous power ratg refers to the short-term maximum power dissipated durg the on tervals of the pulse width modulated brakg control cycle. The brakg resistor must be able to withstand this dissipation for short tervals (milliseconds). Higher resistance values require proportionately lower stantaneous power ratgs. In most applications, brakg occurs only occasionally. This allows the contuous power ratg of the brakg resistor to be much lower than the power ratg of the Drive. It is essential, though, that the stantaneous power ratg and energy ratg of the brakg resistor are sufficient for the most extreme brakg duty that is likely to be encountered. STEP 7 STEP 8 Select a value of resistance for the brakg resistor that is not less than the specified mimum resistance. Larger resistance values may give a cost savg, as well as a safety benefit the event of a fault the brakg system. Brakg capability will then be reduced, which may cause the Drive to trip durg brakg. If this occurs, refer to Deceleration rate Chapter 2 of the User Guide. Estimate the average power that will be dissipated the resistor. Make a note of this step number and the average power to be dissipated the resistor. Thermal protection circuit for the brakg resistor The thermal protection circuit must disconnect the AC supply from the Drive if the resistor becomes overloaded. Figure 2 2 shows a typical circuit arrangement. Figure 2 2 Start / Reset Stop Optional RFI filter Thermal protection device Brakg resistor Drive Typical protection circuit for a brakg resistor Issue code: gpiu2 Installg the Drive 2-11

18 Enclosure layout STEP 9 Use one of the followg enclosure layouts, dependg on the requirements of the stallation: STEP 10 Route EMC precautions Refer to Figure 2 3 which shows the recommended layout for two Drives, and the signal and power cables. Compliance with EMC emission standards Refer to Figure 2 4 which shows the recommended layout for two Drives, two RFI filters, and the signal and power cables. Decide whether the enclosure is to be sealed or ventilated, as follows: A sealed enclosure can give a high gressprotection ratg, but with reduced heat removal capabilities. If possible, locate heatgeneratg equipment (other than brakg resistors) the lower part of the enclosure to encourage ternal convection. If necessary, a taller enclosure, and/or air-circulation fans side the enclosure, can be used. For calculatg the mimum size of sealed enclosure that will adequately cool the Drive(s), refer later this chapter to Calculatg the size of a sealed enclosure. If a high gress-protection ratg is not required, a ventilated enclosure can be used with a fan to supply forced air coolg; this can give a lower ambient temperature than a sealed enclosure. For calculatg the mimum required volume of coolg air, refer later this chapter to Calculatg the air-flow a ventilated enclosure. STEP 11 For compliance with EMC emission standards, ensure the enclosure is fitted with an unpated metal back-plate for mountg the Drive and RFI filter. For example, a zc plated steel back-plate is suitable (see Figure 2 4). Ensure the Drive is stalled vertically for best flow of coolg air through the Drive and heatsk. STEP 12 STEP 13 Note Ensure the clearances around the Drive are as follows: Above and below: 100mm (4 ) Both sides: 5mm ( 1 / 4 ) When surface mountg a model size 3, allow a clearance of 150mm (6) above the Drive; this is required for dismountg. A mimum clearance of 100mm (4) is required for ventilation. For overall dimensions and weights of the Drive and RFI filter, see Appendix C Data. When compliance with EMC emission standards is required, the RFI filter must be stalled at the specified position for each Drive (see Figure 2 4). STEP 14 When a brakg resistor is to be used, it can be stalled outside or side the enclosure. When stalled side, it must be mounted the upper part of the enclosure to prevent it heatg the other equipment by convection. STEP Installg the Drive Issue code: gpiu2

19 Optional brakg resistors as required for the Drives External: Mount on top surface of enclosure. Internal: Mount top part of enclosure. Overload protection device Drives Ensure mimum clearances are respected. 100mm (4) 5mm (¼) 5mm (¼) Back-plate System controller Locate as required. Signal cables Plan for all signal cables to be routed at least 300mm (12) distant from any power cable. 100mm (4) Power cables AC supply isolator, contactor, and fuses or MCBs Locate as required. Location of optional termal block Alternative location of fuses or MCBs Locate as required. Enclosure Figure 2 3 Recommended layout for route EMC precautions (wirg recommendations are given Figure 2 21) Issue code: gpiu2 Installg the Drive 2-13

20 Optional brakg resistors as required for the Drives External: Mount on top surface of enclosure. Internal: Mount top part of enclosure. Overload protection device Drives and RFI filters Ensure mimum clearances are respected. Alternative location of fuses or MCBs Locate as required. 5mm (¼) 100mm (4) 5mm (¼) System controller Locate as required. 5mm (¼) Signal cables Plan for all signal cables to be routed at least 300mm (12) distant from any power cable. 150mm (6) RFI filters Install a separate RFI filter for each Drive. Power cables AC supply isolator, contactor, and fuses or MCBs Locate as required. Alternative location of fuses or MCBs Locate as required. Back-plate Location of optional termal block Enclosure Figure 2 4 Recommended layout for compliance with EMC emission standards (wirg recommendations are given Figures 2 22 and 2 23) 2-14 Installg the Drive Issue code: gpiu2

21 2.4 Calculatg the enclosure size STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 Add the dissipation figures from step 4 of Planng the stallation for each Drive that is to be stalled the enclosure. Make a note of this step number and the total value. If an RFI filter is to be used with each Drive, add the dissipation figures from step 5 of Planng the stallation for each RFI filter that is to be stalled the enclosure. Make a note of this step number and the total value. If the brakg resistor is to be mounted side the enclosure, add the average power figures from step 8 of Planng the stallation for each brakg resistor that is to be stalled the enclosure. Make a note of this step number and the total value. Make a note of this step number and the total heat dissipation ( Watts) of any other equipment to be stalled the enclosure. Add the heat dissipation figures obtaed (as appropriate) from steps 1, 2, 3 and 4 above. This gives a figure Watts for the total heat that will be dissipated side the enclosure. Make a note of this figure and the step number. Example To calculate the size of an enclosure for the followg: Two GPD 1405 models Each Drive to operate at 4.5kHz PWM switchg frequency RFI filter for each Drive Brakg resistors are to be mounted outside the enclosure Maximum ambient temperature side the enclosure: 40 C Maximum ambient temperature outside the enclosure: 30 C Dissipation of each Drive: 190W (from step 4 Planng the stallation) Dissipation of each RFI filter: 25W (max) (from step 5 Planng the stallation) Total dissipation: 2 x ( ) = 430W The enclosure is to be made from pated 2mm ( 3 / 32 ) sheet steel havg a heat transmission coefficient of 5.5W/m 2 / C. Only the top, front, and two sides of the enclosure are to be free to dissipate heat. Calculatg the size of a sealed enclosure The enclosure transfers ternally generated heat to the surroundg 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 contact with a wall or floor) can dissipate heat. Calculate the mimum required unobstructed surface area A e for the enclosure from: P A e = k(t - T ) t ext Where: A e Unobstructed surface area m 2 (1m 2 = 10.8 ft 2 ) T ext Maximum expected ambient temperature C outside the enclosure T t Maximum permissible ambient temperature C side the enclosure P Power Watts dissipated by all heat sources the enclosure k Heat transmission coefficient of the enclosure material W/m 2 / C Figure 2 5 Enclosure havg front, sides and top panels free to dissipate heat Insert the followg values: T t 40 C T ext 30 C k 5.5 P 430W The mimum required heat conductg area is then: A = (1m = 3.3 ft) e (40-30) 2 2 = 7.8m (85ft ) Issue code: gpiu2 Installg the Drive 2-15

22 Estimate two of the enclosure dimensions the height (H) and depth (D), for stance. Calculate the width (W) from: W= A - 2HD e H+D Insertg H = 2m and D = 0.6m, obta the mimum width: W= ( ) = 21. m (6ft 10) If the enclosure is too large for the space available, it can be made smaller only by attendg to one or all of the followg: Usg a lower PWM switchg frequency to reduce the dissipation the Drives (return to step 4 Planng the stallation) Reducg the ambient temperature outside the enclosure, and/or applyg forced-air coolg to the outside of the enclosure Reducg the number of Drives the enclosure Removg other heat-generatg equipment Calculatg the air-flow a ventilated enclosure The dimensions of the enclosure are required only for accommodatg the equipment. The equipment is cooled by the forced air flow. Calculate the mimum required volume of ventilatg air from: Example To calculate the size of an enclosure for the followg: Three GPD 3401 models Each Drive to operate at 6kHz PWM switchg frequency RFI filter for each Drive Brakg resistors are to be mounted outside the enclosure Maximum ambient temperature side the enclosure: 40 C Maximum ambient temperature outside the enclosure: 30 C Dissipation of each Drive: 670W (from step 4 Planng the stallation) Dissipation of each RFI filter: 60W (max) (from step 5 Planng the stallation) Total dissipation: 3 x ( ) = 2190W Insert the followg values: T t 40 C T ext 30 C k 1.3 P 2190W Then: V= = 854m / hr (504 ft /m) (1m 3 /hr = 0.59ft 3 /m) 3kP V= T -T t ext Where: V Air-flow m 3 per hour T ext Maximum ambient temperature C outside the enclosure T t Maximum ambient temperature C side the enclosure P Power Watts dissipated by all heat sources the enclosure k Ratio of p P I 0 Where: P 0 is the air pressure at sea level P I is the air pressure at the stallation Typically use a factor of 1.2 to 1.3, to allow also for pressure-drops dirty air-filters Installg the Drive Issue code: gpiu2

23 2.5 Installg the Drive and RFI filter The termal cover(s) of all models must be removed for access to the electrical connectors. Liftg the Drive Warng The weights of model sizes 3 and 4 are 22kg (49 lbs) and 70kg (154 lbs) respectively. Use appropriate safeguards when liftg these models. Removg the termal covers The Drive is fitted with one or two termal covers dependg on the model size. When model sizes 1, 3 and 4 are through-panel mounted, the termal cover(s) must first be removed order for access to be gaed to the lower mountg holes. Figure 2 7 View from the underside showg how a termal cover is removed from the Drive Remove termal covers, as follows: 1. Workg on either side of the termal cover, push the ner edge of the cover firmly outward until it becomes unclipped. 2. Swg the side of the cover outward and upward until the remag clips become released. 3. Remove the gland plate (you may need to replace it later). Figure 2 6 Removg the termal covers Issue code: gpiu2 Installg the Drive 2-17

24 Mountg brackets supplied with the Drive Table 2 8 Model size 1 General views of the mountg brackets Through-panel M6 Surface M6 Surface-mountg the Drive 1. Use the two surface-mountg brackets. These are manufactured from metal. Ensure the brackets make direct electrical contact with the back-plate; for example, tap M6 ( 1 / 4 ) threaded holes the back-plate the positions shown Figure 2 10 to accept the mountg screws. (For model size 1, you may use the central or, preferably, the two outer screw holes the mountg bracket.) Upper and lower 2. Insert the surface mountg brackets to the slots the top and bottom of the Drive heatsk, as shown Figure M6 M6 3 M6 Upper and lower M6 Upper M6 Figure 2 8 General representation showg the fittg of a surface mountg bracket a heatsk 3. Reta the mountg brackets to the back-plate usg electrically conductg screws. 4 M6 Lower M8 Note When surface mountg a model size 3, allow a clearance of 150mm (6) above the Drive; this is required for dismountg. A mimum clearance of 100mm (4) is required for ventilation. Upper M8 Lower Rear view of the brackets (except for the lower bracket for model size 4). The brackets are not shown to scale Installg the Drive Issue code: gpiu2

25 This page is tentionally not used Issue code: gpiu2 Installg the Drive 2-19

26 Model size 1 Back-plate Model size 2 Back-plate Figure 2 9 Surface mountg of model sizes 1 and Installg the Drive Issue code: gpiu2

27 Model size 3 Back-plate Model size 4 Back-plate Figure 2 10 Surface mountg of model sizes 3 and 4 Issue code: gpiu2 Installg the Drive 2-21

28 Back-plate Model size 1 Back-plate Model size 2 Figure 2 11 Through-panel mountg of model sizes 1 and Installg the Drive Issue code: gpiu2

29 Model size 3 Back-plate Model size 4 Back-plate Figure 2 12 Through-panel mountg of model sizes 3 and 4 Issue code: gpiu2 Installg the Drive 2-23

30 Through-panel mountg the Drive 1. Cut an aperture the back-plate as shown Figure 2 11 or 2 12 as appropriate. 2. Use the through-panel mountg bracket. This is manufactured from metal and is used to secure the top of the Drive to the back-plate; the bottom of the Drive is secured to the backplate by screw(s) passed through a hole the casg and heatsk. Ensure the bracket and heatsk make direct electrical contact with the back-plate; for example, tap M6 ( 1 / 4 ) threaded holes the back-plate the positions shown Figure 2 11 or 2 12 to accept the mountg screws. 3. Insert the through-panel mountg bracket to the recess the top of the Drive heatsk, as shown Figure If a seal is required between the Drive and the back-plate, attach the foam sealg strip (supplied with the Drive) around the edges of the aperture the back-plate so that the flange on the heatsk will press agast the foam strip. 5. Insert the Drive to the aperture. 6. Secure the bottom of the Drive to the panel usg electrically conductg screw(s). 7. Secure the through-panel mountg bracket to the panel usg electrically conductg screw(s). Caution Fittg a baffle plate When the Drive is throughpanel mounted, a baffle plate must be fitted at the rear of the heatsk. Warng If the Drive has been used, the heatsk may be hot. Human contact with the heatsk should be restricted. When the Drive is through-panel mounted, the fittg of a baffle plate causes the heatsk to act as a chimney; this enhances the air flow along the heatsk fs to aid coolg (this naturally occurs when the Drive is surface mounted). You may make a baffle plate from any suitable conductg or non-conductg material and attach it to the heatsk by the method described overleaf. Figure 2 13 General representation showg the fittg of a through-panel mountg bracket the top of the Drive 2-24 Installg the Drive Issue code: gpiu2

31 Figure 2 14 Dimensions for the fabrication of baffle plates for model sizes 1 and 2 Attachg a fabricated baffle plate to the heatsk Table 2 10 Model size Methods of attachg the baffle plate Method of attachment Use the surface mountg brackets. Use M6 x 12mm max (or equivalent) thread-formg screws to screw to the holes the heatsk, or tap the holes to a suitable thread size. Figure 2 15 Dimensions for the fabrication of baffle plates for model sizes 3 and 4 Issue code: gpiu2 Installg the Drive 2-25

32 This page is tentionally not used 2-26 Installg the Drive Issue code: gpiu2

33 Mountg the RFI filter The RFI filters can be surface-mounted only. Mount the RFI filter at the specified location relation to the Drive. In the case of filter sizes C to G, ensure the LOAD termals face the Drive. Dimension C D E F G RFI filter size A mm 14 7 / mm 4 1 / 2 335mm 13 3 / 16 25mm 1 6.4mm 1 / 4 B mm 15 1 / mm 4 1 / 2 335mm 13 3 / mm 1 1 / 2 6.4mm 1 / 4 H J W 396mm 15 9 / 16 10mm 3 / 8 50mm 1 15 / mm 16 10mm 3 / 8 75mm 2 15 / 16 Figure 2 16 Prcipal dimensions of RFI filters sizes A and B, and the locations of the termals Issue code: gpiu2 Installg the Drive 2-27

34 Figure 2 17 Prcipal dimensions of RFI filters sizes C toe, and the locations of the termals 2-28 Installg the Drive Issue code: gpiu2

35 Dimension A C mm 9 / 16 RFI filter size D mm 9 / 16 E mm 9 / 16 B 160mm 6 5 / mm 6 5 / mm 6 11 / 16 C 305mm mm mm 15 3 / 4 D 15mm 9 / 16 15mm 9 / 16 15mm 9 / 16 F 12.5mm 1 / mm 1 / 2 20mm 3 / 4 G H J K L M N P Q S T U V W X 6.5mm 1 / 4 145mm 5 11 / mm 11 3 / 16 25mm 1 330mm 13 35mm 1 3 / 8 60mm 2 3 / 8 45mm 1 3 / 4 240mm 9 7 / 16 80mm 3 1 / 8 30mm 1 3 / 16 50mm 2 40mm 1 9 / mm 7 1 / 2 40mm 1 9 / mm 1 / 4 145mm 5 11 / mm 11 3 / 16 25mm 1 330mm 13 35mm 1 3 / 8 60mm 2 3 / 8 45mm 1 3 / 4 240mm 9 7 / 16 80mm 3 1 / 8 30mm 1 3 / 16 50mm 2 40mm 1 9 / mm 7 1 / 2 40mm 1 9 / mm 1 / 4 145mm 5 11 / mm 13 3 / 8 50mm 1 15 / mm 17 5 / 16 35mm 1 3 / 8 65mm 2 9 / 16 70mm 2 3 / 4 300mm / 16 80mm 3 1 / 8 30mm 1 3 / 16 50mm 2 40mm 1 9 / mm 7 7 / 8 40mm 1 9 / 16 Z M5 x 10mm M5 x 10mm M5 x 10mm Termals M8 M8 M10 Issue code: gpiu2 Installg the Drive 2-29