SPX9000 FR10 FR12 Adjustable Frequency Drives

Installation Manual New Information MN04003018E For more information visit: www.eatonelectrical.com

SPX9000 FR10-FR12 Adjustable Frequency Drives Important Notice Please Read The product discussed in this literature is subject to terms and conditions outlined in Eaton Electrical Inc. selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Eaton Electrical Inc. selling policy. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton Electrical Inc. be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice. Cover Photo: Cutler-Hammer SPX9000 AF Drives. MN04003018E For more information visit: www.eatonelectrical.com i

SPX9000 FR10-FR12 Adjustable Frequency Drives Table of Contents LIST OF FIGURES......................................................... LIST OF TABLES.......................................................... SAFETY................................................................. Definitions and Symbols............................................... Hazardous High Voltage............................................... Cautions............................................................ CHAPTER 1 OVERVIEW How to Use This Manual............................................... 1-1 Receiving and Inspection............................................... 1-1 Product Handling..................................................... 1-3 Open SPX9000 Catalog Numbers........................................ 1-4 CHAPTER 2 INSTALLATION REQUIREMENTS Space Requirements.................................................. 2-1 Environmental Requirements........................................... 2-1 Standard Installation Instructions........................................ 2-2 CHAPTER 3 INSTALLING AC CHOKES..................................... 3-1 CHAPTER 4 INSTALLING POWER MODULE Preparing the Enclosure............................................... 4-1 Mounting the Power Module........................................... 4-3 Grounding the Power Module........................................... 4-4 Connecting Internal Power Cables....................................... 4-5 CHAPTER 5 INSTALLING CONTROL UNIT FOR FRAME 12 UNITS Mounting the Control Unit FR12......................................... 5-1 Connecting Power Supply and Internal Control Cables...................... 5-2 CHAPTER 6 EXTERNAL POWER CONNECTIONS Installing Mounting Plate and Input Terminals............................. 6-1 Installing Fuses....................................................... 6-2 Installing EMC Grounding (European Installations)......................... 6-2 CHAPTER 7 AIR COOLING AND VENTILATION.............................. 7-1 Steering the Internal Air Flow........................................... 7-2 CHAPTER 8 DIMENSIONAL DRAWINGS Power Unit.......................................................... 8-1 AC Chokes........................................................... 8-4 Control Unit......................................................... 8-6 iii iv v v v vi ii For more information visit: www.eatonelectrical.com MN04003018E

SPX9000 FR10-FR12 Adjustable Frequency Drives List of Figures Figure 1-1: Parts Included in Delivery......................................... 1-2 Figure 1-2: Lifting the Power Module......................................... 1-3 Figure 1-3: Lifting the AC Choke............................................. 1-4 Figure 3-1: Installing AC Choke.............................................. 3-2 Figure 4-1: Preparing the Enclosure for the Power Module....................... 4-1 Figure 4-2: Mounting the Power Module...................................... 4-3 Figure 4-3: Grounding the Power Module..................................... 4-4 Figure 4-4: Connecting the Power Cables Between the AC Choke and the Power Unit..................................................... 4-5 Figure 5-1: Connecting Power Supply and Control Cables to the Control Unit........ 5-2 Figure 5-2: Connecting Fiber Optic Cables..................................... 5-3 Figure 5-3: Connecting Power Supply and Control Cables to the Control Unit, FR12..................................................... 5-4 Figure 6-1: Power Input Terminals............................................ 6-1 Figure 6-2: Installing EMC Grounding......................................... 6-2 Figure 7-1: Ventilation Arrangements on the Enclosure (Example)................. 7-1 Figure 7-2: Arrangements for Steering Hot Air to the Outlet at the Top of the Enclosure.................................................... 7-2 Figure 7-3: Roof Structure Seen from the Side................................. 7-3 Figure 8-1: 9000X Dimensions, FR10 Open Chassis.............................. 8-1 Figure 8-2: 9000X Dimensions, FR11 Open Chassis.............................. 8-2 Figure 8-3: 9000X Dimensions, FR12 Open Chassis.............................. 8-3 Figure 8-4: Dimensions of AC Choke CHK0520 in Inches (mm).................... 8-4 Figure 8-5: Dimensions of AC Choke CHK0400 in Inches (mm).................... 8-5 Figure 8-6: Dimensions of AC Choke CHK0261 in Inches (mm).................... 8-5 Figure 8-7: Control Unit Dimensions in Inches (mm)............................. 8-6 Figure 8-8: Internal Fiber Cable Connections, FR10 and FR11..................... 8-7 Figure 8-9: Internal Fiber Cable Connections, FR12.............................. 8-8 MN04003018E For more information visit: www.eatonelectrical.com iii

SPX9000 FR10-FR12 Adjustable Frequency Drives List of Tables Table 1-1: SPX9000 Adjustable Frequency Drives, Frames FR10 FR12............ 1-5 Table 2-1: Enclosure Data for FR10........................................... 2-1 Table 2-2: Enclosure Data for FR11........................................... 2-1 Table 2-3: Enclosure Data for FR12........................................... 2-2 Table 3-1: Choke Types.................................................... 3-1 Table 4-1: Power Module Dimension Requirements in Inches (mm)................ 4-2 Table 4-2: Required Cable Sizes for the Internal Power Cables, 194 F (90 C) Rating Recommended....................................... 4-6 Table 6-1: Copper Bus Bars................................................. 6-1 Table 6-2: Fuse Recommendations........................................... 6-2 Table 7-1: Ventilation Requirements.......................................... 7-2 Table 7-2: Heat Dissipation from the AC Choke................................. 7-3 Table 7-3: Temperatures Measured During an Accepted Test Run................. 7-3 Table 8-1: Dimensions for 9000X, FR10 Open Chassis........................... 8-1 Table 8-2: Dimensions for 9000X, FR11 Open Chassis........................... 8-2 Table 8-3: Dimensions for 9000X, FR12 Open Chassis........................... 8-3 Table 8-4: Choke Types..................................................... 8-4 iv For more information visit: www.eatonelectrical.com MN04003018E

SPX9000 FR10-FR12 Adjustable Frequency Drives Safety Read this manual thoroughly and make sure you understand the procedures before you attempt to install, set up, or operate this Cutler-Hammer SPX9000 Adjustable Frequency Drive from Eaton s electrical business. Definitions and Symbols WARNING This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you and other persons operating this equipment. Read the message and follow the instructions carefully. Hazardous High Voltage This symbol is the Safety Alert Symbol. It occurs with either of two signal words: CAUTION or WARNING, as described below. WARNING Indicates a potentially hazardous situation which, if not avoided, can result in serious injury or death. CAUTION Indicates a potentially hazardous situation which, if not avoided, can result in minor to moderate injury, or serious damage to the product. The situation described in the CAUTION may, if not avoided, lead to serious results. Important safety measures are described in CAUTION (as well as WARNING). WARNING Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing drives and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery. MN04003018E For more information visit: www.eatonelectrical.com v

SPX9000 FR10-FR12 Adjustable Frequency Drives Cautions CAUTION Do not place the control unit close to the power cables. The power cables may disturb the data communications and cause false alarms. CAUTION Be careful when connecting the fiber optic cables! Connecting the wire incorrectly will damage power electronic components. CAUTION It is of utmost importance for the operation and lifetime of the adjustable frequency drive that the enclosure is well ventilated to keep the temperature below maximum allowed operating temperature. Repeated overheating will shorten the lifetime of the converter. vi For more information visit: www.eatonelectrical.com MN04003018E

Chapter 1 Overview This manual provides instructions for the installation of Cutler-Hammer SPX9000 FR10 to FR12 Adjustable Frequency Drives in a switchgear or any other enclosure. This chapter describes the purpose and contents of this manual, the receiving inspection recommendations and the Cutler-Hammer SPX9000 catalog numbering system. How to Use This Manual The purpose of this manual is to provide you with information necessary to install, set and customize parameters, start up, troubleshoot and maintain the Cutler-Hammer SPX9000 drive from Eaton s electrical business. To provide for safe installation and operation of the equipment, read the safety guidelines at the beginning of this manual and follow the procedures outlined in the following chapters before connecting power to the SPX9000. Keep this operating manual handy and distribute to all users, technicians and maintenance personnel for reference. Chapter 1 Overview is the chapter you are reading now. Chapter 2 Installation Requirements Chapter 3 Installing AC Chokes Chapter 4 Installing Power Module Chapter 5 Installing Control Unit for Frame 12 Units Chapter 6 External Power Connections Chapter 7 Air Cooling and Ventilation Chapter 8 Dimensional Drawings Receiving and Inspection The standard delivery includes: The power module with the integrated control unit, referred to as Power Module AC choke(s) FR12 units only: optical cable set for internal control connections between power modules Chassis Module Installation Manual SVX9000 AF Drives User Manual MN04003018E For more information visit: www.eatonelectrical.com 1-1

Power Module AC Choke Control Unit Figure 1-1: Parts Included in Delivery Left: AC Choke Right: Power Module with Integrated Control Unit Optional equipment is delivered on request: Door installation kit for installing the control panel on the enclosure door. Control unit with plate delivered separately. Cable set, including seven optical cables and a 24V connecting cable, readily connected to the power module and the control unit. Standard length: 90 in. (2.3m). If the delivery does not correspond to your order, please contact your Eaton representative. The product is delivered packed in a plywood case, which can be recycled. Instructions for receiving, handling and storing the product, as well as the general warranty terms can be found in Chapter 2. 1-2 For more information visit: www.eatonelectrical.com MN04003018E

Product Handling Lifting the Power Module The power module can be lifted by the holes on top of the module. Fasten the module symmetrically in at least two holes. The lifting equipment must be able to carry the weight of the power module: FR10 = 265 lbs. (123 kg) FR11 = 465 lbs. (123 kg) FR12 = 2 x 265 lbs. (2 x 123 kg) Note: The power module can temporarily rest on the cooling fan assembly, but shocks or non-vertical forces may cause damage to the fans. Figure 1-2: Lifting the Power Module MN04003018E For more information visit: www.eatonelectrical.com 1-3

Lifting AC Chokes The AC choke can be lifted by the two eyebolts on top of the unit. The weight of the AC choke is: CHK0261 = 120 lbs. (53 kg) CHK0400 = 190 lbs. (84 kg) CHK0520 = 255 lbs. (115 kg) Open SPX9000 Catalog Numbers Figure 1-3: Lifting the AC Choke Catalog numbers are located on the power module and the control unit. Refer to the SVX9000 AF Drives User Manual for an explanation of the catalog numbers. SPX9000 FR10 and FR11 Adjustable Frequency Drives require one power module. FR12 requires two power modules. Therefore, for FR12, you will need twice as many drive accessories (such as cables, terminals, chokes, etc.) as you do for FR10 and FR11, unless otherwise stated. Some types of FR11 require two chokes mounted parallel to each other. 1-4 For more information visit: www.eatonelectrical.com MN04003018E

The following Adjustable Frequency Drives comprise the SPX9000 product series FR10 to FR12: Table 1-1: SPX9000 Adjustable Frequency Drives, Frames FR10 FR12 Catalog Number Frame Size CT hp VT hp Nominal Current Choke Type Voltage Range 380 500V SPX250 4 FR10 250 300 385A CHK0400 SPX300 4 FR10 300 460A CHK0520 SPX350 4 FR10 350 400 520A CHK0520 SPX400 4 FR11 400 500 590A 2 x CHK0400 SPX500 4 FR11 500 650A 2 x CHK0400 SPX550 4 FR11 600 730A 2 x CHK0400 SPX600 4 FR12 600 820A 2 x CHK0520 SPX650 4 FR12 700 920A 2 x CHK0520 SPX700 4 FR12 700 800 1030A 2 x CHK0520 Voltage Range 525 690V SPX200 5 FR10 200 250 261A CHK0261 SPX250 5 FR10 250 300 325A CHK0400 SPX300 5 FR10 300 400 385A CHK0400 SPX400 5 FR11 400 450 460A CHK0520 SPX450 5 FR11 450 500 502A CHK0520 SPX500 5 FR11 500 590A 2 x CHK0400 SPX550 5 FR12 600 650A 2 x CHK0400 SPX600 5 FR12 600 700 750A 2 x CHK0400 SPX700 5 FR12 700 800 820A 2 x CHK0400 The Adjustable Frequency Drives can be installed in any enclosure that fulfils the requirements specified in Chapter 2. In the illustrations in this manual, Rittal TS8 is used as an example enclosure. MN04003018E For more information visit: www.eatonelectrical.com 1-5

1-6 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 2 Installation Requirements Space Requirements Refer to Tables 2-1, 2-2, and 2-3 for information on the space required around the enclosure to ensure proper air circulation and cooling. Environmental Requirements Refer to Air Cooling and Ventilation in Chapter 7 for information on product heat dissipation, required operating temperature, cooling air, and humidity. Note: EN60439-1 specifies the ambient temperature for enclosed products at 95 F (35 C) [(24h average)/104 F (40 C) (maximum)]. The ventilation and cooling of the installation room must be sufficient to keep the temperature below this level. Enclosure Table 2-1: Enclosure Data for FR10 Item Table 2-2: Enclosure Data for FR11 Specification Width Min. 23.62 in. (600 mm) Depth Min. 23.62 in. (600 mm), or min. 19.29 in. (490 mm) if the control unit is installed in front of the power unit, otherwise, min. 19.3 inches (490 mm). Height Min. 70.87 in. (1800 mm) if the AC choke is installed beneath the power module, otherwise min. 59.06 in. (1500 mm) Mechanical requirements The enclosure must be able to support a total equipment weight of 607 lbs. (275 kg) (if the power module and the AC choke are installed in the same enclosure). Protective class This manual applies to NEMA Type 1. Construction According to EN60439-1 Ventilation openings Refer to Air Cooling and Ventilation in Chapter 7. Item Specification Width Min. 31.5 in. (800 mm) Depth Min. 23.62 in. (600 mm), or min. 19.29 in. (490 mm) if the control unit is installed in front of the power unit, otherwise, min. 19.3 inches (490 mm). Height Min. 70.87 in. (1800 mm) if the AC choke is installed beneath the power module, otherwise min. 59.06 in. (1500 mm) Mechanical requirements The enclosure must be able to support a total equipment weight of 772 lbs. (350 kg) (if the power module and the AC choke are installed in the same enclosure). Protective class This manual applies to NEMA Type 1. Construction According to EN60439-1 Ventilation openings Refer to Air Cooling and Ventilation in Chapter 7. MN04003018E For more information visit: www.eatonelectrical.com 2-1

Table 2-3: Enclosure Data for FR12 Item Specification Width Min. 47.24 in. (1200 mm) Depth Min. 23.62 in. (600 mm), or min. 19.29 in. (490 mm) if the control unit is installed in front of the power unit, otherwise, min. 19.3 inches (490 mm). Height Min. 70.87 in. (1800 mm) if the AC choke is installed beneath the power module, otherwise min. 59.06 in. (1500 mm) Mechanical requirements The enclosure must be able to support a total equipment weight of 606.27 lbs. (275 kg) (if the power module and the AC choke are installed in the same enclosure). Protective class This manual applies to NEMA Type 1. Construction According to EN60439-1 Ventilation openings Refer to Air Cooling and Ventilation in Chapter 7. Standard Installation Instructions Installing SPX9000 FR10-FR12 Adjustable Frequency Drives in an enclosure involves the following steps: Installing the AC choke(s) Installing and grounding of power module(s) Connecting internal power cables between the AC choke and the power module Preparing for input and output power connections Arranging air-cooling and ventilation Dimensional drawings are found in Chapter 8. Note: The installation of the Adjustable Frequency Drives must be done by certified electricians. Safety regulations for electrical work must be followed during the installation work. Note: Safe operation and full service lifetime of the product can be guaranteed only if the installation instructions in this manual are followed. Note: The product warranty is not valid if the product is handled in a way that does not comply with the instructions in this manual and the user manual. 2-2 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 3 Installing AC Chokes Table 3-1: Choke Types Catalog Frame Choke Number Size Type Voltage Range 380 500V SPX250 4 FR10 CHK0400 SPX300 4 FR10 CHK0520 SPX350 4 FR10 CHK0520 SPX400 4 FR11 2 x CHK0400 SPX500 4 FR11 2 x CHK0400 SPX550 4 FR11 2 x CHK0400 SPX600 4 FR12 2 x CHK0520 SPX650 4 FR12 2 x CHK0520 SPX700 4 FR12 2 x CHK0520 Voltage Range 525 690V SPX200 5 FR10 CHK0261 SPX250 5 FR10 CHK0400 SPX300 5 FR10 CHK0400 SPX400 5 FR11 CHK0520 SPX450 5 FR11 CHK0520 SPX500 5 FR11 2 x CHK0400 SPX550 5 FR12 2 x CHK0400 SPX600 5 FR12 2 x CHK0400 SPX700 5 FR12 2 x CHK0400 Install the AC choke on the bottom part of the enclosure, close to the rear wall, and somewhat to the left (to allow room for later installation of a fuse switch). See Figure 3-1. Fasten the choke on an assembly plate or mounting rails. MN04003018E For more information visit: www.eatonelectrical.com 3-1

Figure 3-1: Installing AC Choke Note: An upper support plate must be installed above the choke if the enclosure is transported in horizontal position. The support plate must be equipped with air circulation holes. See Figure 7-2 on Page 7-2. 3-2 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 4 Installing Power Module Preparing the Enclosure To facilitate future board replacement and other service work, it is recommended that the power module be mounted on rails. Fasten mounting rails to the sides of the enclosure at distances given under F (from the top) and G (from the bottom) in Table 4-1. Leave a space (A) between the module and the walls on both sides for the internal cooling air circulation. A A E B F C G D Figure 4-1: Preparing the Enclosure for the Power Module The power module should be fastened to the rear side of the enclosure as shown in Figure 4-1. For this purpose, install two mounting bars on the rear wall of the enclosure at appropriate levels. MN04003018E For more information visit: www.eatonelectrical.com 4-1

Note: The following dimensions that are essential for placing the power module. All dimensions in inches (mm): Table 4-1: Power Module Dimension Requirements in Inches (mm) A B C D E F G 1.97 (50) 3.94 (100) 44.09 (1120) 21.65 (550) 4.57 (116) 36.14 11.42 (290) 1.73 (44) (918) 33.46 (850) 23.23 (590) A = Minimum distance to the side walls or adjacent components. See note below. Note that the two enclosures, in which the modules of frame FR12 are installed, require no clearance between them. B = Minimum distance from the top of the enclosure; This space is needed for the power cables (see Figure 4-4). C = Module height. D = Minimum distance. See notes below. Minimum distance from the bottom of the enclosure if the AC choke is installed at the bottom of the enclosure. Minimum distance from the bottom of the enclosure if the AC choke is installed in a location other than the bottom of the enclosure. E = Minimum distance. See notes below. Minimum distance from the enclosure door; this is to enable the control unit to be installed in front of the power module. Minimum distance from the door if the control unit is installed in any other location. F = Minimum distance from the mounting rails to top of the enclosure. E = Minimum distance. See notes below. Minimum distance from the mounting rails to the bottom of the enclosure. If the choke is installed in another location, the distance must not, however, be smaller than this. See also the dimensional drawings in Chapter 8. 4-2 For more information visit: www.eatonelectrical.com MN04003018E

Mounting the Power Module Note: If the space around the power module is narrow, lead the internal power cables along the wall and fasten them in brackets before mounting the power module. See Chapter 6. Mounting Bars Figure 4-2: Mounting the Power Module If the power module is installed before the AC choke, the center of gravity is very high at this stage. Support the enclosure thoroughly during the assembly. MN04003018E For more information visit: www.eatonelectrical.com 4-3

Grounding the Power Module Install a grounding bar at the bottom front of the enclosure. Connect a grounding cable from the grounding connector at the lower right hand side of the power module frame to the ground bar of the enclosure. Use a copper grounding cable with a cross-sectional area of at least 1.38 in. 2 (35 mm 2 ) per power module, which obeys the local regulations for grounding cables. See Figure 4-3. Note: The ground bar must be connected to external ground at the installation site according to local guidelines. Ground Bar Grounding Cable Figure 4-3: Grounding the Power Module 4-4 For more information visit: www.eatonelectrical.com MN04003018E

Connecting Internal Power Cables Connect three power cables according to Figure 4-4 to the output terminals of the AC choke and the input terminals of the power module. It is recommended to use cables designed for 194 F (90 C). Connect the L1 cable from the L1 terminal of the AC choke to the L1 input terminal of the power module, the L2 cable to the L2 terminal, and the L3 cable to the L3 terminal. Note: The choke has two sets of output terminals designed for different voltages/frequencies. Use the upper set for 500V/50Hz, 525V/50Hz, 600V/60Hz, and 690V/50Hz and the lower set for 400V/50Hz and 480V/60Hz. L3 L2 L1 L1L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 Voltage/Frequency 500V/50 Hz 525V/50 Hz 575V/60 Hz 690V/50 Hz Voltage/Frequency 400V/50 Hz 480V/60 Hz Figure 4-4: Connecting the Power Cables Between the AC Choke and the Power Unit MN04003018E For more information visit: www.eatonelectrical.com 4-5

Table 4-2: Required Cable Sizes for the Internal Power Cables, 194 F (90 C) Rating Recommended CT hp Voltage Temperature Rating Cu Cables Cable Size, AWG/MCM (mm 2 ) per phase 200, 250, 300, 350 380 500V 194 F (90 C) 00 2 x (70) 525 690V 158 F (70 C) 000 2 x (95) 300, 350, 450 380 500V 194 F (90 C) 000 2 x (95) 525 690V 158 F (70 C) 250 MCM 2 x (120) 400, 500, 550, 600, 700 380 500V 194 F (90 C) 00 2 x (70) 525 690V 158 F (70 C) 000 2 x (95) 600, 650, 700 380 500V 194 F (90 C) 000 2 x (95) 525 690V 158 F (70 C) 250 MCM 2 x (120) 4-6 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 5 Installing Control Unit for Frame 12 Units Note: Cutler-Hammer SPX9000 FR10-FR11 drives are delivered with the control unit integrally mounted on the power unit. FR12 units have the control module separated from the power unit and attached to the mounting box so that it can be installed it to a sidewall or the frame of the enclosure. Mounting the Control Unit FR12 If needed, connect the 24V connecting cable and the fiber optic cables to the power module before mounting the control unit. See Connecting Power Supply and Internal Control Cables on Page 5-2. Fasten the mounting box with the control unit to a sidewall or to the frame of the enclosure. The standard length of the connecting cable and the fiber optic cables is 90.55 in. (2.3m), which means that the control unit must be placed within this distance from the power module. Pay attention to the minimum bending radius of the fiber optic cables (see Figure 5-1). CAUTION Do not place the control unit close to the power cables. The power cables may disturb the data communication and cause false alarms. MN04003018E For more information visit: www.eatonelectrical.com 5-1

Connecting Power Supply and Internal Control Cables The control unit uses 24V DC supplied from the ASIC board, which is located on the left side of the power unit. To access the board, remove the protective cover in front of the power module. Connect the power supply cable to the X10 connector on the ASIC board and to the X2 connector on the rear side of the control unit. Protective Cover X10 1 2 3 4 5 6 7 X2 Min. Bending Radius 2.0 (50) Figure 5-1: Connecting Power Supply and Control Cables to the Control Unit Each fiber optic cable has a number 1 7 marked on the cable shield at both cable ends. Connect each cable to the connectors marked with the same number 1 7 on the ASIC board and on the rear side of the control unit. The list of the optic signals can be found in Chapter 8. 5-2 For more information visit: www.eatonelectrical.com MN04003018E

Power Unit ASIC Board D-Connector for Control Unit Mounting Box Fiber Cable Terminals Figure 5-2: Connecting Fiber Optic Cables CAUTION Be careful when connecting the fiber optic cables! Connecting the wires incorrectly will damage power electronic components. Note: The minimum bending radius for optical cables is 2.0 in. (50 mm). Attach the cable bundle at two or more points, at least one at each end, to prevent damages to the cables. Fasten the protective cover on the power unit when complete. MN04003018E For more information visit: www.eatonelectrical.com 5-3

Min. Bending Radius 2.0 (50) Power Module 1 ASIC Board Star Coupler Board FB Board Power Module 2 ASIC Board Figure 5-3: Connecting Power Supply and Control Cables to the Control Unit, FR12 Each fiber optic cable has a number 1 8 and 11 18 marked on the cable shield at both cable ends. Connect each cable to the connectors marked with the same number on the ASIC board and on the rear side of the control unit. Additionally, you may have to connect the 4 fiber cables from the fieldbus board to the star coupler board. Refer to Chapter 8 for the list of optic signals. 5-4 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 6 External Power Connections Installing Mounting Plate and Input Terminals For further installation of other devices (breakers, fuses, EMC grounding), it is recommended that an installation plate be mounted in front of the AC choke, leaving the bottom part open for air circulation. Install input terminals on the plate and connect them to the input terminals (the uppermost terminals) of the AC choke using bus bars or flexible bus bars according to Table 6-1. Table 6-1: Copper Bus Bars Product Voltage range 380 500V SPX250 4 SPX300 4 SPX350 4 SPX400 4 SPX550 4 SPX600 4 SPX700 4 Voltage range 525 690V SPX200 5 SPX300 5 SPX400 5 SPX500 5 SPX550 5 SPX700 5 Cu bus bar, size 1.18 in. x 0.24 in. (30 x 6 mm) 1.57 in. x 0.24 in. (40 x 6 mm) 1.57 in. x 0.24 in. (40 x 6 mm) 2 pcs 1.18 in. x 0.24 in. (30 x 6 mm) 2 pcs 1.57 in. x 0.24 in. (40 x 6 mm) 1.18 in. x 0.24 in. (30 x 6 mm) 1.57 in. x 0.24 in. (40 x 6 mm) 2 pcs 1.18 in. x 0.24 in. (30 x 6 mm) L1 L2 L3 Figure 6-1: Power Input Terminals MN04003018E For more information visit: www.eatonelectrical.com 6-1

Installing Fuses The power module contains no internal fuses. To protect the device and allow the installation of a main switch in the enclosure, it is recommended that a fuse switch be installed. Use R- type fuses according to Table 6-2, and install them in the same enclosure as the adjustable frequency drive, or in another enclosure in the immediate vicinity. Table 6-2: Fuse Recommendations Product Fuse Ratings Current [A] Voltage I 2 t at V n Recommended Fuse Types (or equivalent) SPX250 4 SPX300 4 SPX350 4 SPX400 4 700 1100 1400 700 600V 600V 600V 600V 425000 1350000 2600000 425000 Bussmann 170M5813 (3 pcs) Bussmann 170M8552 (3 pcs) Bussmann 170M8548 (3 pcs) Bussmann 170M5813 (6 pcs) SPX500 4 SPX550 4 SPX600 4 SPX650 4 700 700 1000 1250 600V 600V 600V 600V 425000 425000 945000 1950000 Bussmann 170M5813 (6 pcs) Bussmann 170M5813 (6 pcs) Bussmann 170M6814 (6 pcs) Bussmann 170M8547 (3 pcs) SPX700 4 SPX200 5 SPX250 5 SPX300 5 1400 700 700 700 600V 600V 600V 600V 2600000 425000 425000 425000 Bussmann 170M8548 (3 pcs) Bussmann 170M5813 (3 pcs) Bussmann 170M5813 (3 pcs) Bussmann 170M5813 (3 pcs) SPX400 5 SPX450 5 SPX500 5 SPX550 5 1100 1250 700 700 600V 600V 600V 600V 1350000 1950000 425000 425000 Bussmann 170M8552 (3 pcs) Bussmann 170M8547 (3 pcs) Bussmann 170M5813 (6 pcs) Bussmann 170M5813 (6 pcs) SPX600 5 SPX700 5 700 700 600V 600V 425000 425000 Bussmann 170M5813 (6 pcs) Bussmann 170M5813 (6 pcs) Installing EMC Grounding (European Installations) The output cables to the motor must be 360 EMC grounded. The EMC grounding clamps can, for instance, be installed on the mounting plate in front of the AC choke as shown in Figure 6-2. The EMC grounding clamps must be suited to the output cable diameter to give a 360 contact with the cables. Refer to the SVX9000 AF Drives User Manual for output cable diameters. EMC Grounding Grounding Bar Cable Clamps Figure 6-2: Installing EMC Grounding 6-2 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 7 Air Cooling and Ventilation CAUTION It is of utmost importance for the operation and lifetime of the adjustable frequency drive that the enclosure is well ventilated to keep the temperature below the maximum operating temperature. Repeated overheating will shorten the lifetime of the converter. 2 A 1 B Figure 7-1: Ventilation Arrangements on the Enclosure (Example) The enclosure door must be provided with air vents for air intake. To achieve sufficient cooling inside the enclosure, the dimensions for the total area of free openings for incoming air given in Table 7-1 must be followed. For instance, there could be two screened vents as shown in Figure 7-1 (Eaton s recommendation). This layout ensures a sufficient air flow to the module fans as well as cooling of the additional components. Air outlet vents must be situated on top of the enclosure. The minimum effective air outlet area per converter frame is given in Table 7-1. The cooling arrangements inside the enclosure must be such that they prevent hot output air from mixing with the incoming fresh air (see Figure 7-2). The ventilation vents must fulfil the requirements set by the selected protection class. The examples in this manual apply to protection class NEMA Type 1. MN04003018E For more information visit: www.eatonelectrical.com 7-1

During operation, air is sucked in and circulated by a fan blower at the bottom of the power unit. If the power unit is placed in the upper part of the enclosure, the fan blower will be in the mid of the enclosure, at the height of the upper ventilation grid. Table 7-1: Ventilation Requirements Steering the Internal Air Flow FR10 FR11 FR12 1A 20 in. x 10 in. 30 in. x 10 in. 40 in. x 20 in. 1B (510 mm x 255 mm) (765 mm x 255 mm) (1020 mm x 570 mm) 2 110 in. 2 (700 cm 2 ) 165 in. 2 (1050 cm 2 ) 220 in. 2 (1400 cm 2 ) Total 160 in. 2 (1000 cm 2 ) 235 in. 2 (1500 cm 2 ) 310 in. 2 (2000 cm 2 ) Cooling air must be sucked in through the ventilation openings on the door and blown out at the top of the enclosure. To steer the hot air from the power unit to the outlet at the top of the enclosure and prevent it from circulating back to the fan blower, use either of the following arrangements: 1. Install a closed air duct from the power unit to the outlet on top of the enclosure (A in Figure 7-2). 2. Install shields in the vents between the power unit and the enclosure walls (B in Figure 7-2). Place the shields above the air outlet vents at the sides of the module. Air Duct Sheet Metal Touch Protection Cover Shields Mesh Type Touch Protection Choke Upper Support Figure 7-2: Arrangements for Steering Hot Air to the Outlet at the Top of the Enclosure Note: To allow free air circulation, the touch cover at the bottom of the enclosure must be of type meshed sheet metal screen. For the same reason, the bus bar touch protection cover and the choke upper support must be equipped with holes. See Figure 7-2. Note: If a flat roof is used, mount a V-shaped air guide on the underside of the roof to direct the air flow horizontally. See Figure 7-3. 7-2 For more information visit: www.eatonelectrical.com MN04003018E

Figure 7-3: Roof Structure Seen from the Side Heat Dissipation The efficiency of the adjustable frequency drive is a function of switching frequency, operating frequency and load (see SVX9000 AF Drives User Manual). Based on this information, heat dissipation can be calculated at a certain operating point. For most cases the following general formula based on adjustable frequency drive load can be used to estimate the heat dissipation of the power module: P loss [kw] = P mot [kw] *0.025 Table 7-2 shows the heat dissipation from the AC choke. Table 7-2: Heat Dissipation from the AC Choke Choke Heat Dissipation CHK0261 CHK0400 CHK0520 460 W 570 W 810 W Temperatures Measured During Test Run The following table shows the temperatures measured during a test run of a 520A/400V unit with nominal load @50/60 Hz. The test unit was installed in a Rittal TS8 enclosure following the guidelines described in this manual. Table 7-3: Temperatures Measured During an Accepted Test Run Measurement Temperature ( C) Note Ambient Air 88.8 F (29.9 C) Outside enclosure Fan Intake Air 97.2 F (36.2 C) Module Input Terminal 137.5 F (58.6 C) L2-phase Output Terminal 149 F (65.3 C) V-phase AC Choke 198.1 F (92.3 C) L2 winding surface MN04003018E For more information visit: www.eatonelectrical.com 7-3

7-4 For more information visit: www.eatonelectrical.com MN04003018E

Chapter 8 Dimensional Drawings Power Unit H5 H3 H4 W3 W2 W5 W1 H7 H2 H1 H6 W4 D3 D4 D2 D1 Figure 8-1: 9000X Dimensions, FR10 Open Chassis Table 8-1: Dimensions for 9000X, FR10 Open Chassis Frame Size Voltage hp (CT) FR10 480V 250 350 19.7 575V 200 300 (500) Approximate Dimensions in Inches (mm) W1 W2 W3 W4 W5 H1 H2 H3 H4 H5 H6 H7 D1 D2 D3 D4 16.7 (425) 1.2 (30) 2.6 (67) 12.8 (325) 45.9 (1165) 44.1 (1121) 34.6 (879) 33.5 (850).7 (17) 24.7 (627) 10.8 (275) 19.9 (506) 17.9 (455) 16.7 (423) 16.6 (421) MN04003018E For more information visit: www.eatonelectrical.com 8-1

Shown without terminal cover W2 W2 W2 W2 W3 W3 H2 W1 H1 D2 D1 Figure 8-2: 9000X Dimensions, FR11 Open Chassis Table 8-2: Dimensions for 9000X, FR11 Open Chassis Approximate Dimensions in Inches (mm) Frame Size Voltage W1 H1 D1 H2 D2 W2 W3 FR11 480V 27.9 575V (709) 45.5 (1155) 19.8 (503) 33.5 (850) 18.4 (468) 8.86 (225) 2.6 (67) 8-2 For more information visit: www.eatonelectrical.com MN04003018E

H5 H3 H4 W3 W2 W5 W1 H7 H2 H1 H6 W4 D3 D4 D2 D1 Table 8-3: Dimensions for 9000X, FR12 Open Chassis Frame Size Voltage hp (CT) FR10 480V 250 350 19.7 575V 200 300 (500) Figure 8-3: 9000X Dimensions, FR12 Open Chassis Approximate Dimensions in Inches (mm) W1 W2 W3 W4 W5 H1 H2 H3 H4 H5 H6 H7 D1 D2 D3 D4 16.7 (425) 1.2 (30) 2.6 (67) 12.8 (325) 45.9 (1165) 44.1 (1121) Note: Cutler-Hammer SPX9000 Adjustable Frequency Drive frame FR12 is built of two FR10 modules. 34.6 (879) 33.5 (850).7 (17) 24.7 (627) 10.8 (275) 19.9 (506) 17.9 (455) 16.7 (423) 16.6 (421) MN04003018E For more information visit: www.eatonelectrical.com 8-3

AC Chokes Table 8-4: Choke Types Catalog Number Voltage Range 380-500V SPX 250 4 SPX 300 4 SPX 350 4 SPX 400 4 SPX 500 4 SPX 550 4 SPX 600 4 SPX 650 4 SPX 700 4 Voltage Range 525-690V SPX 200 5 SPX 250 5 SPX 300 5 SPX 400 5 SPX 450 5 SPX 500 5 SPX 550 5 SPX 600 5 SPX 700 5 Frame Size FR10 FR10 FR10 FR11 FR11 FR11 FR12 FR12 FR12 FR10 FR10 FR10 FR11 FR11 FR11 FR12 FR12 FR12 Choke Type CHK0400 CHK0520 CHK0520 2 x CHK0400 2 x CHK0400 2 x CHK0400 2 x CHK0520 2 x CHK0520 2 x CHK0520 CHK0261 CHK0400 CHK0400 CHK0520 CHK0520 2 x CHK0400 2 x CHK0400 2 x CHK0400 2 x CHK0400 CHK0520 6.50 (165) 6.50 (165).24 (6) 8.03 (204) 1.69 (43) 19.57 (497) 1 1 1 5.70 (145) 9.61 (244) 3.03 (77).83 (21).55 (14).79 (20).79 (20) 15.71 (399) 1.58 (40) 2 3 3 3 7.88 (200) 2 2 17.57 (446) Figure 8-4: Dimensions of AC Choke CHK0520 in Inches (mm) 8-4 For more information visit: www.eatonelectrical.com MN04003018E

CHK0400.24 (6) 9.37 (238) 1.54 (39) 4.72 (120) 4.72 (120) 13.79 (350) 1 1 1 2.64 (67).75 (19) 13.94 (354).59 (15).59 (15) 1.18 (30) 3 3 3 2 2 2 16.58 15.08 (421) (383) 5.51 (140) 10.31 (262) 5.90 (150) 10.83 (275) Figure 8-5: Dimensions of AC Choke CHK0400 in Inches (mm) CHK0261.16 (4) 8.11 (206) 1.54 (39) 4.72 (120) 4.72 (120) 13.94 (354) 1 1 1 2.44 (62).59 (15) 1.18 (30) 3 3 3 14.06 12.56 11.30 (357) (319) (287).59 (15) 2 2 2.39 (10) 4.25 (108) 9.06 (230).75 (19) Min. 5.90 (150) 10.83 (275) Figure 8-6: Dimensions of AC Choke CHK0261 in Inches (mm) MN04003018E For more information visit: www.eatonelectrical.com 8-5

Control Unit.33 (8.5).33 (8.5) 2.32 (59).63 (16) 11.82 (300) 12.94 (328.5) 2.52 (64) 5.75 (146) Figure 8-7: Control Unit Dimensions in Inches (mm) 8-6 For more information visit: www.eatonelectrical.com MN04003018E

Fiber Optic Cables, Signal Lists, and Connections You might need to connect or re-connect the internal fiber cables if you have ordered your SPX9000 adjustable frequency drive FR10 or FR11 with the control unit separated from the power module. In FR12, consisting of two power modules, you will have to establish the fiber cable connections from the star coupler board to the other power module. See Chapter 4. Connect the cables according to the figures below. Terminals on Power Unit ASIC Board H1 H2 H3 H4 H5 H6 H7 Gate control enable Phase U control Phase V control Phase W control ADC synchronization DataBus data from control board to ASIC DataBus data from ASIC to control board H1 H2 H3 H4 H5 H6 H7 Fiber Adapter Board on Control Unit H1 H2 H3 H4 H5 H6 H7 H8 Gate control enable Phase U control Phase V control Phase W control ADC synchronization DataBus data from control board to ASIC DataBus data from ASIC to control board Not Used H1 H2 H3 H4 H5 H6 H7 H8 Figure 8-8: Internal Fiber Cable Connections, FR10 and FR11 MN04003018E For more information visit: www.eatonelectrical.com 8-7

Star Coupler Board on Control Unit H8 Terminals on ASIC Board of Power Module 1 H8 Trip signal from power module 1 H7 DataBus data from ASIC 1 to control board H6 DataBus data from control board to ASIC 1 H5 ADC synchronization, power module 1 H4 Phase W control, power module 1 H3 Phase V control, power module 1 H2 Phase U control, power module 1 H1 Gate control enable, power module 1 H18 Trip signal from power module 2 H17 DataBus data from ASIC 2 to control board H16 DataBus data from control board to ASIC 2 H15 ADC synchronization, power module 2 H14 Phase W control, power module 2 H13 Phase V control, power module 2 H12 Phase U control, power module 2 H11 Gate control enable, power module 2 H23 FeedBack phase W H22 Feedback phase V H21 Feedback phase U H7 H6 H5 H4 H3 H2 H1 H18 H17 H16 H15 H14 H13 H12 H11 H23 H22 U V W T H1 H2 H3 H4 H5 H6 H7 H1 H2 H3 H4 H5 H6 H7 H8 H1 H2 H3 H4 H5 H6 H7 U V W T H1 H2 H3 H4 H5 H6 H7 T Gate control enable Phase U control Phase V control Phase W control ADC synchronization DataBus data from control board to ASIC DataBus data from ASIC to control board Feedback phase U Feedback phase V Feedback phase W Trip signal Terminals on ASIC Board of Power Module 2 Gate control enable Phase U control Phase V control Phase W control ADC synchronization DataBus data from control board to ASIC DataBus data from ASIC to control board Trip signal H21 Figure 8-9: Internal Fiber Cable Connections, FR12 8-8 For more information visit: www.eatonelectrical.com MN04003018E

Company Information Eaton s electrical business is a global leader in electrical control, power distribution, and industrial automation products and services. Through advanced product development, world-class manufacturing methods, and global engineering services and support, Eaton s electrical business provides customer-driven solutions under brand names such as Cutler-Hammer, Powerware, Durant, Heinemann, Holec and MEM, which globally serve the changing needs of the industrial, utility, light commercial, residential, and OEM markets. For more information, visit www.eatonelectrical.com. Eaton Corporation is a diversified industrial manufacturer with 2004 sales of $9.8 billion. Eaton is a global leader in fluid power systems and services for industrial, mobile and aircraft equipment; electrical systems and components for power quality, distribution and control; automotive engine air management systems, powertrain solutions and specialty controls for performance, fuel economy and safety; and intelligent truck drivetrain systems for safety and fuel economy. Eaton has 55,000 employees and sells products to customers in more than 125 countries. For more information, visit www.eaton.com. Eaton Electrical Inc. 1000 Cherrington Parkway Moon Township, PA 15108-4312 USA tel: 1-800-525-2000 www.eatonelectrical.com 2005 Eaton Corporation All Rights Reserved Printed in USA Publication No. MN04003018E/CPG